Show Us Your Homemade Battery Housing

Hello crew,

My second battery box build...

Luis.

tomjasz said:

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!

Click to expand...

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?

John and Cecil said:

tomjasz said:

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!

Click to expand...

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?

Click to expand...

They are snug enough if you follow the directions. I use a plastic top and bottom and zip ties. All good...

tomjasz said:

They are snug enough if you follow the directions. I use a plastic top and bottom and zip ties. All good...

Click to expand...

Ahh zipties, good idea Thanks, I will look into them as well when I build my next battery.

bikehedz said:

more of the same

Click to expand...

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.

soaresdacosta said:

Hello crew,

My second battery box build...

Luis.

Click to expand...

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

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.

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

https://www.google.com/search?q=surplus+military+cooler&num=100&newwindow=1&prmd=ivns&source=lnms&tbm=isch&sa=X&ved=0ahUKEwiWwceGnajfAhXpxFQKHV8OA1sQ_AUIBQ

Sent from my iPhone using Tapatalk

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.

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... :lol:

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!






Pulling my negative wire straight down earned me a boo boo. I layered another nickel strip over that.


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.


All the parts of the box that I ended up with:


Drilled and tapped six of these to hold the side panels on.


I showed my wife a few choices on vinyl, and this was her favorite


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.


Empty box:


Full box, and I still hope to tuck all these wires and plugs in around the edge


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

Oooooo clever touch with the vinyl siding! That's a relatively easy way to make an aluminum box look fantastic!

scrap vinyl siding is thrown out at construction sites!

Nice tip!

markz said:

scrap vinyl siding is thrown out at construction sites!

Nice tip!

Click to expand...

I updated my post with a parts list. The vinyl is an adhesive roll as opposed to house siding.

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:



Then a bit of carbon fiber :



A 3D printed Box for the BMS:



A whole lot of time for sanding, making brackets:


And so far it looks like this:





Not finished yet but I basically just have to add the insulating material and close the lid.

These are my battery boxes

1/8" mdf - https://www.homedepot.com/p/1-8-in-x-4-ft-x-10-ft-MDF-Board-279211/205889965
Gorilla Tape - https://www.amazon.ca/dp/B07WGJJT73?tag=duc12-20&linkCode=osi&th=1&psc=1
*Now, if you get the wider gorilla tape then you be styling properly.
Hose clamps are a nice bonus but zip ties work well too, black if you in vogue. 120lb variety if you feel the need to splurge.
Get the 500pk and your set. Maybe some stainless steel so no crack head can twist the battery off. Hence hose clamps.



What a masterful piece of handiwork. V2.0 I got black gorilla tape hiding the shiny.

Dui said:

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.

Click to expand...

Very nice!

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

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

https://endless-sphere.com/forums/viewtopic.php?f=6&t=97658&p=1430364#p1430364

Naturally red

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

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-bicycles-baja-trike-292424-1.htm

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

https://www.ebay.com/itm/1x3000W-72V-BLDC-Motor-Kit-with-Brushless-Controller-for-Electric-Scooter-E-Bike/202991999101?ssPageName=STRK%3AMEBIDX%3AIT&var=503180563321&_trksid=p2057872.m2749.l2649

Mounted on a 1/8 aluminum plate

https://www.ebay.com/itm/1-8-x-15-x-20-Aluminum-Plate-125-5052-Aluminum/322764599069?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2057872.m2749.l2649


It will be street legal.






I got my inspiration from one of The Inja videos

https://www.youtube.com/watch?v=oXQrK5CCDfY

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 ?