Kona mid drive with tidy battery and enclosure

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.



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/viewtopic.php?f=31&t=68865



Drilled holes in the desk to hold the welding rods. Safe and accessible



Battery Tester



Created a battery jig to keep the dimensions of the pack when gluing them together.
Worked out well.



Battery

14S 5P Panasonic NCR18650PF cells

The cells for this build are from member tumich, Thanks
https://endless-sphere.com/forums/viewtopic.php?f=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.







The Battery Box

Constructed out of 1/8 inch board, tacked together with hot glue then Fibreglass overtop.



View attachment 20

View attachment 19

On goes the fibreglass





Grommet hole

Nobody likes a sloppy hard to install grommet that falls out after the first ride.



Metal reinforcement inserted into the box, this is where it will be bolted to the water bottle nutserts.



Filled, filed and sanded smooth



Primer



Paint



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.



Grommet hole came out nice

View attachment 10



Watertight seal inside the lid



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.



Built up shoulders and one layer of foam to prevent squeaks and to fully lock the box into the frame

Front



Back



The Bike

Thats Chris' sweet Kona Stinky on the right





Slim







Thanks for checking out my build

Matt

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.
Do you know the final weight of the enclosure, net without batteries?

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

fesanand said:

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.
Do you know the final weight of the enclosure, net without batteries?

Click to expand...

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

Lurkin said:

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

Click to expand...

Thanks Lurkin

The first of many battery builds I hope.