dirtdad
1 kW
- Joined
- Mar 2, 2008
- Messages
- 309
I am working on overhauling my eBike of burden (see avatar). One of the changes will involve making a battery box. I have come up with a good general method that I find pretty easy based on input from ES members, no less. The major tools needed are a drill, metal saw (I use a Dremmel) and a pop riveter. Plus I am looking for ways to fix one problem in particular, please read on.
1) If possible, get 2 aluminum project enclosures that fit 2 of the 3 dimensions of the final box. Think of them as trays or end caps. If you cannot find enclosures, or if they are simply too expensive, you can make the same kind of thing by pop riveting L section aluminum found at many hardware stores.
2) Get L section project aluminum to connect the 2 caps, completing the frame of the box. Additional cross beams of aluminum strips may be needed for additional strength. Secure aluminum using pop rivets.
Other details: I am using dense thin foam on the bottom of the box to protect the batteries from the pop rivets. I have constructed the box so that I can mount charging and discharging ports on the box and contain a switch with a resistor across it and a fuse inside. You could also completely enclose the battery with additional material and use a hinge/latch on one side for easy access. My box is being strapped below the downtube for a low center of gravity and to center the weight for as low a moment as possible.
In the example below I started with a project box the right size, but the size of the batteries changed mid project so the overall box is kind of strange, but it will work and demonstrate what I am talking about.
In this particular case, I would like to see if I can improve on the design. The pipe clamps that secure the frame to the box stick out past the ends of the box. It is not that bad, really, I plan to cover them with rubber feet or something, and my legs and feet stay well clear of them while riding.
But it would be nice to make them more flush. I would attach them to the sides of the box, but it is important the bolts attach the way they do, so that as I tighten them, the box is held more securely to the frame. I might make them attach to the top of the box, but the box is full of battery. Acessing the internal bolt to tighten/loosen is impossible. Mabye some clever hardware choice would make that possible. I was thinking of cutting access holes in the box itself, but there has to be a better way.
1) If possible, get 2 aluminum project enclosures that fit 2 of the 3 dimensions of the final box. Think of them as trays or end caps. If you cannot find enclosures, or if they are simply too expensive, you can make the same kind of thing by pop riveting L section aluminum found at many hardware stores.
2) Get L section project aluminum to connect the 2 caps, completing the frame of the box. Additional cross beams of aluminum strips may be needed for additional strength. Secure aluminum using pop rivets.
Other details: I am using dense thin foam on the bottom of the box to protect the batteries from the pop rivets. I have constructed the box so that I can mount charging and discharging ports on the box and contain a switch with a resistor across it and a fuse inside. You could also completely enclose the battery with additional material and use a hinge/latch on one side for easy access. My box is being strapped below the downtube for a low center of gravity and to center the weight for as low a moment as possible.
In the example below I started with a project box the right size, but the size of the batteries changed mid project so the overall box is kind of strange, but it will work and demonstrate what I am talking about.
In this particular case, I would like to see if I can improve on the design. The pipe clamps that secure the frame to the box stick out past the ends of the box. It is not that bad, really, I plan to cover them with rubber feet or something, and my legs and feet stay well clear of them while riding.
But it would be nice to make them more flush. I would attach them to the sides of the box, but it is important the bolts attach the way they do, so that as I tighten them, the box is held more securely to the frame. I might make them attach to the top of the box, but the box is full of battery. Acessing the internal bolt to tighten/loosen is impossible. Mabye some clever hardware choice would make that possible. I was thinking of cutting access holes in the box itself, but there has to be a better way.
