Battery packs - aluminium extrusions

[Jestronix]

So with a recent purchase of LIPO, I got started on my battery packs.

I bought 12 x 6s 5200ah multistar packs on special, should give me some nice range.

One thing i have never liked about LIPO on bikes is they are soft and catch on fire if damaged. So in order to seperate my LIPO for the hard world outside, i have popped them in 50x50mm aluminum extrusions. Fitting 3 packs to give me 18s. I will mount these on my bottom bar.

They are short enough to fit on my bottom and top bars.

Here they are installed in the extrusions.

They were a major squeeze to get them in, I had to remove the covers and use some grease, I also had to bend the ends of the aluminium so the it wouldn't catch and puncture the cells. They slide in with some force, but are very tightly packed.

As u can see it's a tight spot. But handy as they don't move around inside the case.

This will keep the batts safe if I come off the bike or something flicks up. they are light and don't add much weight.

 

[dogman dan]

I LIKE IT!

You will get some movement for awhile, which could chafe a hole in a cell. Soon enough though, those packs will puff ever so slightly, at which point you are never getting them out of the box again. They won't rub anymore at all by then. 8)

 

[speedmd]

I am also using aluminum box extrusion as a battery box. Mine is open on the top side and I use a velcro strap to hold everything down. Not pretty but it is working very well and sticks can not get to the soft packs. If I stay with it, was thinking of covering the alloy with carbon fabric or even the fake carbon decorative tape to make it look more finished.

 

[Jestronix]

Yeh I thought of open top but I want to limit the flames if they were to catch fire, I'd still say it would be a wild fireworks display , I'm having thoughts about some kinda of fireproof gel or cloth.

These cells will see about 3c max so loads will be low and I'll be keeping the cycle depths low as possible.

I'd be impressed to ever see these cells ever move around, I had to mallet them in , yes mallet! I also made sure I removed all the burs from when I cut the aluminium.

I have run similar packs that did well.