Kona mid drive with tidy battery and enclosure

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mushymelon   1 kW

1 kW
Posts: 300
Joined: Mar 28 2010 3:46am
Location: Southern Ontario, Canada

Kona mid drive with tidy battery and enclosure

Post by mushymelon » Nov 16 2015 2:06am

I would like the thank my friend Chris for creating such an awesome battery box, amazing craftsman and good friend!

Heres some pics of my build I'm gonna start with the battery and enclosure because that whats really special about this build.

I first started with used cells and a Styrofoam prototype to make sure everything is going to fit.
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My welding station

I would like to thank JP, member riba2233 for creating an amazing welder for the diy crowd.
Affordable battery welder that works fantastic and runs on 12v batteries pure genius.

Heres a link to his sale thread
https://endless-sphere.com/forums/viewt ... 31&t=68865
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Drilled holes in the desk to hold the welding rods. Safe and accessible
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Battery Tester
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Created a battery jig to keep the dimensions of the pack when gluing them together.
Worked out well.

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Battery

14S 5P Panasonic NCR18650PF cells


The cells for this build are from member tumich, Thanks
https://endless-sphere.com/forums/viewt ... 31&t=61608

Each cell is wrapped at the bottom and top with filament tape to prevent chaffing they also have stick on paper insulators on the positive ends these are highly recommended.
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The Battery Box

Constructed out of 1/8 inch board, tacked together with hot glue then Fibreglass overtop.
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On goes the fibreglass
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Grommet hole

Nobody likes a sloppy hard to install grommet that falls out after the first ride.
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Metal reinforcement inserted into the box, this is where it will be bolted to the water bottle nutserts.
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Filled, filed and sanded smooth
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Primer
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Paint
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This shot really shows off Chris' skills you can see the channels where it slips into the frame on one side and locks up into place.
There is also a channel for all the shift and brake cables to run hidden above the box. A real work of art.

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Grommet hole came out nice
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Watertight seal inside the lid
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Tidy cables routed stealthily above the box

Batteries a perfect fit too I can remove the panel and swap out a battery in under a minute without any fuss.
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Built up shoulders and one layer of foam to prevent squeaks and to fully lock the box into the frame

Front
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Back
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The Bike

Thats Chris' sweet Kona Stinky on the right
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Slim
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Thanks for checking out my build

Matt

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fesanand   10 W

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Joined: Jun 01 2014 5:48am

Re: Kona mid drive with tidy battery and enclosure

Post by fesanand » Nov 16 2015 3:48am

I wasn't going to expect that result specially seeing the first pictures. Wow! the result is impressive, best detailed-shape enclosure seen so far. Congratulations. :D :D :D :D :D
Do you know the final weight of the enclosure, net without batteries?

Lurkin   100 kW

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Joined: Jan 18 2015 4:31pm
Location: Melbourne, VIC, AUS

Re: Kona mid drive with tidy battery and enclosure

Post by Lurkin » Nov 16 2015 3:53am

Super tidy, well done. Especially a fan of the custom battery welding man bench and testing unit. Awesome!

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mushymelon   1 kW

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Posts: 300
Joined: Mar 28 2010 3:46am
Location: Southern Ontario, Canada

Re: Kona mid drive with tidy battery and enclosure

Post by mushymelon » Nov 16 2015 4:08am

fesanand wrote:I wasn't going to expect that result specially seeing the first pictures. Wow! the result is impressive, best detailed-shape enclosure seen so far. Congratulations. :D :D :D :D :D
Do you know the final weight of the enclosure, net without batteries?
Haha ya the prototype battery and box was just to make sure the battery would fit the way I planned.
It also served as a good reference point when constructing the real enclosure.

I didn't weigh it but its very light around a pound i think.

Thanks for the kind words.

Matt

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mushymelon   1 kW

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Posts: 300
Joined: Mar 28 2010 3:46am
Location: Southern Ontario, Canada

Re: Kona mid drive with tidy battery and enclosure

Post by mushymelon » Nov 16 2015 4:10am

Lurkin wrote:Super tidy, well done. Especially a fan of the custom battery welding man bench and testing unit. Awesome!
Thanks Lurkin

The first of many battery builds I hope.

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