200km Trek build with custom aluninum battery box

[rwaudio]

It's finally done so I figured I'd show off the results.
The bike is a Trek DS8.6 which is a great platform for a cruiser/commuter.
Motor is a Bafang 750w mid drive kit
Battery is a custom 18650 pack 14S13P using Samsung 2.6Ah cells (1.75kwh)
Battery box is a custom aluminum triangle to hold the massive battery. Using the dual water bottle mounts I think it's a pretty clean install.

 

[ColinB]

It looks super, but can the four bottle mounts in an aluminum frame handle the weight? I have no idea. I've had aluminum pannier racks break (twice, in different spots), carrying 10 lbs of battery. I assume you have the controller in the case?
Colin

 

[rwaudio]

It looks super, but can the four bottle mounts in an aluminum frame handle the weight? I have no idea. I've had aluminum pannier racks break (twice, in different spots), carrying 10 lbs of battery. I assume you have the controller in the case?
Colin

I don't see how they would break, but I guess only time will tell.
The controller is built into the motor, the battery is the only thing in the box.

 

[soaresdacosta]

Nicely done. Very well finish.
No paint, or carbon-vinil ?
Take care.

 

[rwaudio]

Nicely done. Very well finish.
No paint, or carbon-vinil ?
Take care.

The bikes owner liked the look of the raw brushed aluminum so much that we left it that way.
Mine was built in the same style on a similar Trek and will be painted black. If he prefers the aluminum look it will just get clear coat or anodized, otherwise it might end up black as well.
I've been looking at vinyl wrap, I think that's and interesting option too, I'd be curious to see examples of a vinyl wrapped box on a bike.

 

[chucho]

Nicely done. Very well finish.
No paint, or carbon-vinil ?
Take care.

The bikes owner liked the look of the raw brushed aluminum so much that we left it that way.
Mine was built in the same style on a similar Trek and will be painted black. If he prefers the aluminum look it will just get clear coat or anodized, otherwise it might end up black as well.
I've been looking at vinyl wrap, I think that's and interesting option too, I'd be curious to see examples of a vinyl wrapped box on a bike.

Here is the first bike i did some years ago. It has aluminiun box vinyl wrapped and used the bottle mounts also :wink: It is still working hard after 3 years. The carbon vinyl of 3m is perfect for this aplication.

 

[rwaudio]

Thanks for the pic chucho, I may have to look into that.
I'm starting the proper battery box for my fat bike, maybe I'll plan to wrap that one.
The current tool bag is functional but I need to work on the actual battery and box for the bike.

 

[soaresdacosta]

My battery box, and a lot of other parts, is wrapped in 3m carbon vinil.

 

[rwaudio]

My battery box, and a lot of other parts, is wrapped in 3m carbon vinil.

That looks sweet, thanks for sharing, I'm going to have to try vinyl wrap now!!