Show Us Your Homemade Battery Housing

General Discussion about electric bicycles.
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soaresdacosta   1 kW

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Re: Show Us Your Homemade Battery Housing

Post by soaresdacosta » May 21 2018 10:52am

Hello crew,

My second battery box build...

Luis.
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John and Cecil   1 kW

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Re: Show Us Your Homemade Battery Housing

Post by John and Cecil » May 21 2018 11:33am

tomjasz wrote:
May 21 2018 1:03am
Neodymium magnets dislike heat, as long as the pack never gets a hot cell or 3, all is well. Batteryblocs are quite large and take up space. But they do work. I like the V2 Vruzend for a more compact solderless build, and no magnets.

Bob’s box rocks! I like it!
Yes I saw those as well. My concern with those is that the caps just slide over the ends and they are not clamped from ones side to the other sandwiching the battery between them. I would be concerned that they might lose contact with the battery over time from bumps, expansion, etc?

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tomjasz   10 GW

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Re: Show Us Your Homemade Battery Housing

Post by tomjasz » May 21 2018 4:27pm

John and Cecil wrote:
May 21 2018 11:33am
tomjasz wrote:
May 21 2018 1:03am
Neodymium magnets dislike heat, as long as the pack never gets a hot cell or 3, all is well. Batteryblocs are quite large and take up space. But they do work. I like the V2 Vruzend for a more compact solderless build, and no magnets.

Bob’s box rocks! I like it!
Yes I saw those as well. My concern with those is that the caps just slide over the ends and they are not clamped from ones side to the other sandwiching the battery between them. I would be concerned that they might lose contact with the battery over time from bumps, expansion, etc?
They are snug enough if you follow the directions. I use a plastic top and bottom and zip ties. All good...
Thanks Justin_le we're here thanks to you. All the best to the mods for their tireless work keeping it on an even keel.

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John and Cecil   1 kW

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Re: Show Us Your Homemade Battery Housing

Post by John and Cecil » May 21 2018 5:30pm

tomjasz wrote:
May 21 2018 4:27pm

They are snug enough if you follow the directions. I use a plastic top and bottom and zip ties. All good...
Ahh zipties, good idea :) Thanks, I will look into them as well when I build my next battery.

bikehedz   100 µW

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Re: Show Us Your Homemade Battery Housing

Post by bikehedz » Jul 31 2018 6:12am

bikehedz wrote:
Aug 03 2017 2:10am
more of the same
Looking at doing the same. Lost this one in a fire. Has anyone adapted a through post ring swing arm to drop outs for a mxus 3kw?
Any help would be appreciated for my next build.
20161213_193738 copya.jpg

n2mb   100 W

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Re: Show Us Your Homemade Battery Housing

Post by n2mb » Jul 31 2018 8:52pm

soaresdacosta wrote:
May 21 2018 10:52am
Hello crew,

My second battery box build...

Luis.
Any more details on that battery box build? It looks good.

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pwd   1 kW

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Re: Show Us Your Homemade Battery Housing

Post by pwd » Sep 27 2018 12:37pm

It is not a full enclosure but it fits my em3ev triangle pack nicely. Its just some 22 gauge steel bent up to fit the bike frame and fastened with u bolts. There are some metal loops fastened to the side to anchor the hook and loop straps that secure the battery down.
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Commuter/Street Build viewtopic.php?f=6&t=98286:
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amberwolf   100 GW

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Re: Show Us Your Homemade Battery Housing

Post by amberwolf » Dec 17 2018 8:31pm

Another potential existing casing people can use; surplus military coolers:

https://www.google.com/search?q=surplus ... A1sQ_AUIBQ

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Samd   1.21 GW

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Re: Show Us Your Homemade Battery Housing

Post by Samd » Dec 17 2018 11:16pm

Image


Sent from my iPhone using Tapatalk
http://ballaratebikes.com/

ImageImageImage
"Knowledge is knowing that a tomato is a fruit. Wisdom is knowing that a 165mm rear shock can't deliver 220mm of rear swingarm travel." - Oprah Winfrey.

taylorh-rl   1 µW

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Re: Show Us Your Homemade Battery Housing

Post by taylorh-rl » Mar 09 2019 2:16pm

I'm totally new to electrical bikery so you'll notice the ridiculously heavy Apex battery array. The crates used to house them but my new lipo arrived yesterday so now it's merely spare storage capacity. I'm thinking of putting an antique typewriter in the front so it can look even more hipster than it does already.

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Bison_69   100 W

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Re: Show Us Your Homemade Battery Housing

Post by Bison_69 » Jun 16 2019 7:21pm

Hi Guys...

Here is my latest version...

Great frame design and battery case space (which is one of the bigest out there... available in 4.25" and 5.25' width)
from http://kobois.com/ (ebikedeal was the old website)

A lot of room... everything fits in there,
Kelly controller 7230S 120A / 300A peak (24 - 90V) programmable wire & Bluetooth,
Hub-motor QS Motor / QS 205 H50 V3 with ferrofluid and hub sink. (inside motor treated with EL601 Red Insulating Varnish Sprayon)
Large Cycle Analyst,
Li-Ion cells VTC4 18650 21S10P (88Vdc @ 21A C-rate 14.3) all cells individually protected with fuse-wire,
AliExpress Smart BMS 16-32S (100-200-300A) programmable with wire or Bluetooth, (with LCD display)
DC-DC module 80V to 12Vdc 10A,
Hi-precision Shunt 150A/75mV,
12Vdc brushless thermostatics fans (adjustable temperature)
4 waters tight air-vents,
Industrial Marine fuse holder (up to 120A)
Polarized junction post,
Industrial panic switch - emergency shut down
Industrial selector switch SPDT 600V-63A (Group Charge - OFF - RUN)
Ignition Switch with key
Main power output connector is Anderson (charging port)
All harness and cables are passed through Nylon strain reliefs...
Power Silicon Cable Hobby King #8AWG
All electrical contacts are covered with NCP-2 battery corrosion preventative and also some Dow Corning electrical dielectric silicon.

Extra informations: I am a pretty heavy guy... (6ft - 248Lbs) and my best top speed reached in summer 2018 was 83Km/h
I have tested the maximum range with one full charge... at average speed 50-55km/h I have made about 60km. (there was 8% charge remaining)

The wheels have been replaced by motorcycle wheels 19'' X 1.6'' with 3.25 tires... it is now safer to ride on the potted holes road where I live... :D :lol:
eBike upgrade 2017_1.jpg
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CityTrackPro 2015 eBike http://kobois.com
QS MOTOR 205 H50 V3 hub-motor
KELLY 7230S 90V 120A (300A peak) Controller w/Bluetooth
Large screen CycleAnalyst
Batteries 18650 VTC4 Li-ion 21S10P
SMART BMS 16-32S / 200A w/Bluetooth and LCD Display
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thundercamel   1 kW

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Re: Show Us Your Homemade Battery Housing

Post by thundercamel » Jun 19 2019 11:12am

I really like the individual cell fuses!

I finally got to rebuilding the StefEbike battery, because I never liked having the second rack over the rear wheel. Making the aluminum battery box has been the most difficult part, using a jigsaw, vise, hammer, drill and tap.

$9.00 Cell holders short ANNPower 18650 10P honeycomb/hexagon holders
$12.00 Cell holders long ANNPower 18650 13P honeycomb/hexagon holders
$6.99 Glue Beacon 873388 Quick Grip All-Purpose Adhesive, 2-Ounce
$50.80 Battery management system SP New Energy Smart 14s 60a Bluetooth BMS
$2.00 Cutting board x2 Dollar tree 11x14" cutting sheets
$39.34 Aluminum Sheet x2 RMP .063 3003 H14 Aluminum Sheet 12" x 24"
$11.84 Threaded couplers uxcell Rod Coupling Nut M6 Hex Coupling Nut 20Pcs
$8.02 Tapered screws uxcell M6x16mm 10.9 Carbon Steel Hex Socket Screw 50pcs
$12.00 Vinyl wrap VViViD XPO Black Metallic Sparkle Gloss Vinyl Wrap Film 1ft X 5ft
$16.98 U shape rubber trim seal 33Ft(10M) Car Door Edge Guards,U Shape Trim Rubber Seal Black

Pictures galore; open as a new tab for full resolution:

Designing an arrangement with the hexagon pattern was fun!
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Pulling my negative wire straight down earned me a boo boo. I layered another nickel strip over that.
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Tried to actually lay out the BMS wires nicely this time and tape everything down. Still haven't bothered to test the PTC fuses that I bought for each BMS wire.
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All the parts of the box that I ended up with:
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Drilled and tapped six of these to hold the side panels on.
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I showed my wife a few choices on vinyl, and this was her favorite :)
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I forced myself to install the 48/36/26 crankset since I wouldn't want to remove this box later to adjust the shifter/derailleur. I'm not sure if the derailleur is supposed to match the chainring size, but I could BARELY get it set to work with all three gears. The original was a 42/34/24. I had to chop the front of the derailleur off so it wouldn't hit the battery box; I don't even know why that's there? The chain only ever touches the lower portion.
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Empty box:
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Full box, and I still hope to tuck all these wires and plugs in around the edge :confused:
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Went for a brief ride in the rain last night! It's definitely got a little more kick to it without as much voltage sag, and the basic battery life LED's don't droop to red whenever you're on throttle anymore. Even though the goal was to get rid of the rack over the rear wheel, we had gotten so used to it that now it looks like something's missing!

Still need to mount the rear tail lights and fenders on both bikes. I'm interested to see how the vinyl will look in direct sunlight, and how the battery temperature will be. With the larger chainring and cleaner overall look, this thing looks made for speed :D

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Last edited by thundercamel on Jun 20 2019 3:10pm, edited 4 times in total.
My Ebike builds - Existing bikes, affordable motor kits, self built 14s6p batteries - Now with more recumbent!

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dequinox   10 kW

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Re: Show Us Your Homemade Battery Housing

Post by dequinox » Jun 19 2019 11:41am

Oooooo clever touch with the vinyl siding! That's a relatively easy way to make an aluminum box look fantastic!
On a dusty pew in a vestibule sits the Devil playing pocket pool, he's waiting for the next poor fool who forgot that it was Sunday

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HI-V (Retired); Sun Cruiser w/ Hill Topper Kit; Giant Simple Cruiser w/ Amazon 1000W Front Hub.
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markz   100 GW

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Re: Show Us Your Homemade Battery Housing

Post by markz » Jun 19 2019 1:32pm

scrap vinyl siding is thrown out at construction sites!

Nice tip!

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thundercamel   1 kW

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Re: Show Us Your Homemade Battery Housing

Post by thundercamel » Jun 20 2019 3:14pm

markz wrote:
Jun 19 2019 1:32pm
scrap vinyl siding is thrown out at construction sites!

Nice tip!
I updated my post with a parts list. The vinyl is an adhesive roll as opposed to house siding.
My Ebike builds - Existing bikes, affordable motor kits, self built 14s6p batteries - Now with more recumbent!

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Dui, ni shuo de dui   1 kW

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Re: Show Us Your Homemade Battery Housing

Post by Dui, ni shuo de dui » Feb 26 2020 9:12pm

Not entirely finished but real close, so I thought I'd share it here too...
So this is the battery box I'm building for my motorbike, It all started up with some blue foam:
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Then a bit of carbon fiber :
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A 3D printed Box for the BMS:
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A whole lot of time for sanding, making brackets:
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And so far it looks like this:
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Not finished yet but I basically just have to add the insulating material and close the lid.
:bolt: :bolt: My electric Ninja 250 clone: 16 000W 72V40Ah A123 cells : :bolt: :bolt:
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:bolt: :bolt: My electric Scooter: 11 000W 72V 50Ah LiFePO4 cells: :bolt: :bolt:
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markz   100 GW

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Re: Show Us Your Homemade Battery Housing

Post by markz » Mar 07 2020 7:32pm


Evoforce   10 kW

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Re: Show Us Your Homemade Battery Housing

Post by Evoforce » May 10 2020 6:19am

Dui, ni shuo de dui wrote:
Feb 26 2020 9:12pm
Not entirely finished but real close, so I thought I'd share it here too...
So this is the battery box I'm building for my motorbike, It all started up with some blue foam:


Not finished yet but I basically just have to add the insulating material and close the lid.
Very nice! :D
"Energy is all consuming and it is never ending. It just changes form as it morphs through time and space... " Evoforce
                                                                                   Several 5403 motors, Phoenix Racer(5403) crystalyte suspension mtn bike LiFepo4 72/20.  (409) crystalyte 48 volt hardtail.   Phoenix Cruiser(5304)  LiFePo4 48/20.  First electric bike a 2009 XB 502-700 style, 36/20 sla scooter bike.  2) 2011 Nissan Leaf's in the mix.  Tesla Model S.  And solar!

john61ct   100 GW

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Re: Show Us Your Homemade Battery Housing

Post by john61ct » May 10 2020 6:48am

As a stronger ziptie / hose clamp replacement

Clamptite tool, plus whatever wire stock

stainless, monel, titanium

you care to pay for.

The big ones you can use coat hanger wire.

Can use for field repairs of your frame tubing out in the bush too 8-)

miro13car   1 MW

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Re: Show Us Your Homemade Battery Housing

Post by miro13car » May 11 2020 1:12pm

I like Soaresdacosta's design of battery box.
box made of anything metal has advantage of heat transfer from cells to outside.
Eplus, Bionx

fourbanger   100 W

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Re: Show Us Your Homemade Battery Housing

Post by fourbanger » May 31 2020 3:14pm


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thundercamel   1 kW

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Re: Show Us Your Homemade Battery Housing

Post by thundercamel » May 31 2020 8:57pm

Naturally red :)
My Ebike builds - Existing bikes, affordable motor kits, self built 14s6p batteries - Now with more recumbent!

john61ct   100 GW

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Re: Show Us Your Homemade Battery Housing

Post by john61ct » Jun 01 2020 8:59am

That's right, make them look like sticks of dynamite. . .

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shntat   1 µW

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Re: Show Us Your Homemade Battery Housing

Post by shntat » Aug 01 2020 10:02pm

My ex-roommate left his ps3 when he moved out so i recycled the bag which holds a 18650 20s13p battery pack.The 18650 cells are 3.7 3000 mah. Perfect fit. I am building a 72v 3000w 24" Sun Baja trike.

Specs for bike

https://www.incycle.com/product/sun-bic ... 2424-1.htm

Here is the motor kit that is going into the basket.

https://www.ebay.com/itm/1x3000W-72V-BL ... 2749.l2649

Mounted on a 1/8 aluminum plate

https://www.ebay.com/itm/1-8-x-15-x-20- ... 2749.l2649


It will be street legal.
:bigthumb: :lowbatt:

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I got my inspiration from one of The Inja videos

https://www.youtube.com/watch?v=oXQrK5CCDfY
Last edited by shntat on Aug 03 2020 2:39am, edited 2 times in total.

999zip999   100 GW

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Re: Show Us Your Homemade Battery Housing

Post by 999zip999 » Aug 02 2020 8:37pm

I need a quarter inch side pipe my neighbor gave me some quarter inch plywood but I just need to protect the side of a pouch. ? It's also in a plastic cage.
3,000 Watt cyc middrive or something else ? It's about money how much ?
What size rear wheels ?
How many watts can the battery support ?

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