Does anybody know of a reliable material that is malleable to work with but strong enough to withstand minimal wear and readily available? Best I can come up with this PVC gutter material wrapped around foam rubber or thick acrylic or plexiglass but then it becomes a little bulky
I've seen cheap Chinese packs (one of which I disassembled) where all cells were hot glued together (no cell holders), surrounded on all sides with something like these 0.5 mm thick fiber boards https://www.aliexpress.us/item/3256...anage-home.0.0&gatewayAdapt=glo2usa4itemAdapt, then taped with masking tape all around, then shrink wrapped.
Edit: I would not skip cell holders. Cell wraps are very thin, if worn through, will create shorts.
Plexiglass holds up well when there is lots of vibration. I had a Boston speaker box with 2 12” woofers. There was a plexiglass window. I could see the action of the woofers working very hard while listening to Rage Against The Machine. The window would shake a lot. I would regularly listen to music at loud volumes. (Sorry, I was that guy in high school). Very forgiving material.
Agree, but I recently made up some small cylindrical batteries. Space considerations and unavailability of round holders required glueing. For extra insulation, I wrapped adhesive fish paper around each 21700 cell and then shrink wrapped a 40mm PVC tube around that. Should be pretty tough.
Agree, but I recently made up some small cylindrical batteries. Space considerations and unavailability of round holders required glueing. For extra insulation, I wrapped adhesive fish paper around each 21700 cell and then shrink wrapped a 40mm PVC tube around that. Should be pretty tough.
Lots of batteries use shrink wrap.
How about lots of layers of stretch wrap instead ? (LLDPE)
Linear low-density polyethylene (LLDPE) is a poor conductor of electricity, meaning it's a good electrical insulator.
Melting point around 120-130°C (248-266°F)
Whereas, the melting point of shrink wrap, typically made of PVC or polyolefin, generally falls within the range of 120-140°C (250-290°F)
machinable. malleable. Fordable bendable will not crack. Bulletproof if thick enuf.
Not acrylic.. thats different. Airplane windshield is poly carbonate ... goose bounces off. Will not crack on impact.
Side windows are acrylic... clear and see through clarity. Will crack on impact.
I have built a few bikes with poly. Its strong as F.
like throw the bike off the side of the road cartwheeling into the yard and you sliding after it. From 60mph when the rear spins out around the turn in the rain. People stopping with phones to call ambulances and stuff.
Wicked bikes! How are you running the motor wires? Looks like you’ve got some heavy gauge phase wire. Are you splicing the phase wires right at the axle? Also, I like the cardboard on the pedals, but do you really ride that Super73 barefoot?
Wicked bikes! How are you running the motor wires? Looks like you’ve got some heavy gauge phase wire. Are you splicing the phase wires right at the axle? Also, I like the cardboard on the pedals, but do you really ride that Super73 barefoot?
Lol. I did like that Super73 thanks. The pedals were expensive, customer bike. I just build it. cannot allow it to get messed up until he gets it lol. That super73 had a Recaro seat, High beam low beam TWO auto horns tailight fuse box and a brake light ( brake actuated.) he spent like 5700$ on it, my labor included, all kinds of high end stuff. It did like 12kW, peak, 55mph... I think. 150A @ 82V.. Sabvoton... I think the BMS said. Shinko street tires. 200A bluetooth BMS, 25aH 1800wH 72V bike. Dual disk brake DNM fork, Magura MT5e, display, remote key fob and alarm... , light kit. Only thing I didnt like was the rear had no suspension. Hardtail.
He rode it for three months and sold it for 4700$. I dont know where it is now. Some happy owner.
Whoa! Awesome looking bike! Though, I'd probably get pulled over and I don't want that. I like the light kit. I was think about lighting up my bike as well. I dont ride at night so that doesnt make much sense to do it. Might be a cool "because I can" moment.
I have built a few bikes with poly. Its strong as F.
like throw the bike off the side of the road cartwheeling into the yard and you sliding after it. From 60mph when the rear spins out around the turn in the rain. People stopping with phones to call ambulances and stuff.
Frame broke. Poly didnt (shrinkwrap i presume?).
Does anybody know of a reliable material that is malleable to work with but strong enough to withstand minimal wear and readily available? Best I can come up with this PVC gutter material wrapped around foam rubber or thick acrylic or plexiglass but then it becomes a little bulky
If this is for the outer casing, then consider GFRP laminate. I did my first battery case from PC, and while it's easy to cut, you can only get so many shapes from joined flat sheets. GFRP is lighter, stronger, allows you to build complex shapes without joins and acts as a great insulator.
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