"PVC pipe" lipo battery case build

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Dreddydave   1 W

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"PVC pipe" lipo battery case build

Post by Dreddydave » Nov 22 2011 6:42am

Long time lurker of the site, and I've learned a lot here so I thought it's time I give something back :)

I've measured up and found that 6s lipo packs fit very well in some rectangular PVC downpipe, so that's been the basis for my latest bike (1000w hub). PVC's cheap and really easy to work with and I think looks pretty good. This first pic is after I've cut the pipe to size with a cheap angle grinder, and attached an aluminium piece to close the top.
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2 x 6s lipos fit snuggly in the pipe on top of each other, but still have a little room for expansion.
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How the 12s2p batteries will fit in the case.
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Velcro straps to hold the battery to the frame. It holds it really well without any movement while riding.
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Added on/off switch and hole for the battery power cables into the other side of the controller, so power goes in one side and out the other.
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Completed controller.
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Controller mounted behind the crank, trying to be stealthy :wink: It hides ok from the crank side.
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Completed bike, crank side
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The next step now is to strip the whole bike again and paint it white, so it matches the battery pack.

miuan   10 kW

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Re: "PVC pipe" lipo battery case build

Post by miuan » Nov 22 2011 6:55am

much less trouble to paint the battery black :mrgreen:

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Pure   10 kW

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Re: "PVC pipe" lipo battery case build

Post by Pure » Nov 22 2011 7:51am

Pretty neat build. I know a lot of people prefer to have some sort of pressure on their LiPo so maybe wrap your packs in something to give them a snug fit. Some guys go as far as to clamp them between plates of plastic. The idea is that not allowing them to swell helps maintain their internal resistance.
miuan wrote:much less trouble to paint the battery black :mrgreen:
LOL I was thinking the same thing.
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Re: "PVC pipe" lipo battery case build

Post by BikeFanatic » Nov 22 2011 8:02am

I love that case. Nice and low, and If you paint it black it will blend well. Very stealth build.

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sn0wchyld   1 MW

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Re: "PVC pipe" lipo battery case build

Post by sn0wchyld » Nov 22 2011 8:24am

nicely done mate, if you have access to a heat gun you can easily heat form it too, if you need some more elaborate shapes.

Hillhater   100 GW

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Re: "PVC pipe" lipo battery case build

Post by Hillhater » Nov 22 2011 6:36pm

Nice pack holder Dave.
One question: .. is there anything (foam ?) between the packs to prevent them sliding around inside the pipe and "mashing" into each other ??
This forum owes its existence to Justin of ebikes.ca

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Beachcruzer   100 W

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Re: "PVC pipe" lipo battery case build

Post by Beachcruzer » Nov 23 2011 12:55am

Very slick. Paint everything matte black. Beauty.

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Dreddydave   1 W

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Re: "PVC pipe" lipo battery case build

Post by Dreddydave » Nov 23 2011 1:00am

Ok, I think I'll go with the general consensus here and paint the battery black! The bike still needs a respray anyway. It'll be a stealth bomber!

I forgot to mention that there's 2 Velcro straps to the seat-tube as well as the 2 on the top tube. It means I just need to rip the Velcro and unplug it from the controller for charging. And yeah, there's foam at each end and in between the cells.

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Alan B   100 GW

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Re: "PVC pipe" lipo battery case build

Post by Alan B » Nov 23 2011 1:02am

Nice idea in this thin wall PVC material. I may have some uses for that. I've seen thicker wall stuff but it gets heavy, this is pretty lightweight looking.

One thing to wrap packs in to provide some pressure and friction and keep them from chafing is 3m Vet Wrap. Like a slightly tack Ace bandage that only sticks to itself this stuff works great and doesn't make a mess when you remove it.

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neptronix   100 GW

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Re: "PVC pipe" lipo battery case build

Post by neptronix » Nov 23 2011 1:03am

NICE!!! I love the ingenuity here.
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Grinhill   10 kW

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Re: "PVC pipe" lipo battery case build

Post by Grinhill » Nov 23 2011 4:22am

Looks good Dave. +1 for the black. :D

Had you seen Hyena's battery case before doing this one? His bike has a couple of PVC pipes strapped to the top tube.
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Dreddydave   1 W

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Re: "PVC pipe" lipo battery case build

Post by Dreddydave » Nov 23 2011 5:37am

Thanks for all the positive comments guys :D

The black GT's replacing my "daily-rider" shown below. It's a 450w MY1018Z brushed motor with a 36v/10Ah LiFeP04, and the bike was found under my house when I bought the place (cleaned up and resprayed by me though!). It's got a free-wheeling crank but doesn't have a freewheel on the motor, so requires the motor running when you want to pedal. 35km/h without pedalling is not bad though, so I only really need to pedal up hills to keep the speed up.

Happy to sell this one now if someone wants to give me a good price and pick it up :wink:
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Whiplash   100 MW

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Re: "PVC pipe" lipo battery case build

Post by Whiplash » Nov 23 2011 9:20am

Does anyone have a link to buying this occur pipe? In the US I have not been able to find it??
Power is a fascinating thing, the more you have, the more you want, but the real power is having the restraint not to use it all at once...............Um...Yeah..

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sn0wchyld   1 MW

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Re: "PVC pipe" lipo battery case build

Post by sn0wchyld » Nov 23 2011 9:31am

Whiplash wrote:Does anyone have a link to buying this occur pipe? In the US I have not been able to find it??

as far as I know it may only be available in aus, I think it was GCinDC that ended up getting hyena to ship some over for him!! Have a call round the local hardware stores, ask for square/rectangular downpipe. Its a shame too, the stuff is great to work with once you add in some pvc cement and some heat...

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Still finishing it off but a damn sight lighter than my old steel case, and much better looking!

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Ykick   100 GW

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Re: "PVC pipe" lipo battery case build

Post by Ykick » Nov 23 2011 9:32am

I've been eyeing something similar found in the fencing supply dept. 4"x4" and 5"x5" square fence and railing PVC posts.
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Re: "PVC pipe" lipo battery case build

Post by wineboyrider » Nov 23 2011 10:26am

I've seen something quite like it in the rain gutter department at Lowe's..... :wink:
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Harold in CR   1 MW

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Re: "PVC pipe" lipo battery case build

Post by Harold in CR » Nov 23 2011 8:51pm

There is a thread over on Elmoto, telling about bending Lexan, same as bending sheet metal. Guy says no heat required. Other guys have tried it and report that they can't believe how easy it is to work with. :shock: :)
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Alan B   100 GW

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Re: "PVC pipe" lipo battery case build

Post by Alan B » Nov 23 2011 9:12pm

Some plastics will bend cold, others not.

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Whiplash   100 MW

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Re: "PVC pipe" lipo battery case build

Post by Whiplash » Nov 23 2011 9:50pm

Yeah, I have seen the 4x4 stuff but its too bulky like that, but maybe, I could cut it in half and use it for the lower battery case and just use Velcro to strap in the batts
Power is a fascinating thing, the more you have, the more you want, but the real power is having the restraint not to use it all at once...............Um...Yeah..

The harder you work.....The luckier you get!!

"People who say it can't be done are often interrupted by those that have already figured out how to do it!"

Email me @ currentcycles@gmail.com
OR check out http://www.CurrentCycles.net

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sn0wchyld   1 MW

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Re: "PVC pipe" lipo battery case build

Post by sn0wchyld » Nov 23 2011 11:04pm

Whiplash wrote:Yeah, I have seen the 4x4 stuff but its too bulky like that, but maybe, I could cut it in half and use it for the lower battery case and just use Velcro to strap in the batts
you can use a goop called PVC CEMENT to glue pieces together - its strong as, if not stronger than the pvc itself. its all thats holding my bat case together, wich is made up of cut and bent 100mm by 50mm pvc pipe. make sure you use a primer before though, otherwise the strength of the bond is compromised...

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Alan B   100 GW

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Re: "PVC pipe" lipo battery case build

Post by Alan B » Nov 23 2011 11:39pm

PVC cement is a solvent cement. It makes a great bond when the joint is thin, not so strong if the joint is thicker.

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gtadmin   10 kW

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Re: "PVC pipe" lipo battery case build

Post by gtadmin » Nov 24 2011 6:43am

:idea: - You can filler rod weld PVC, I've done it before. You use a specialised heat gun that has an outlet of about 6ø and filler rod 3ø, the trick is to get the temperature correct :wink:

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Samd   1.21 GW

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Re: "PVC pipe" lipo battery case build

Post by Samd » Nov 24 2011 9:26pm

Nice one Dreddy Dave,
I have been looking for casings for several hundred old mobile phone batts I have been putting together. Might be a nice thin solution - toolboxes too wide/tall.

PS> Group ride in Melb on the 10th December as a topic under "e-vents" if you are interested.
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Re: "PVC pipe" lipo battery case build

Post by Jimbo » Nov 25 2011 1:00pm

I used the same stuff on my Big Hit - Wickes sell it by the metre here in the UK.

:D

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Dreddydave   1 W

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Re: "PVC pipe" lipo battery case build

Post by Dreddydave » Dec 06 2011 5:51am

I've been pretty busy at work, but with the nicer weather I want to get the bike finished before next week so I can ride it to work. I'm going to be painting everything flat black, including most of the bike parts that are currently chrome.

Stripped:
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It puts the primer on it's skin...
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