Battery Placement Sun Atlas Cargo

[judson]

Hey All,

I have a tricky battery placement to make. The bike is a Sun Atlas Cargo. On my previous build I used a bottle mount battery. This bike (picture attached) does not have nearly enough space in the triangle for that. My kids will be sitting on the rack so that is out. I think I am basically down to behind the seat tube. I have two questions, has anyone mounted a battery in this position on a Sun Atlas Cargo (though the geometry is not too far from other cargo bikes like the Extracycle Edgerunner I suppose)? I have no need to reinvent the wheel if someone has had success with this already.

Second question, if I am going to fabricate something in the way of a platform/enclosure in which to put this battery, what material are people using. My initial thought was thin plywood. Then I thought aluminum and now I am thinking plastic.

Thanks for all the help!!

 

[amberwolf]

I would recommend reading thru the long Show us your Homemade Battery Housing thread, and the Your Creation's Before and After pics thread. Lots of really useful info and ideas there, often with links to the build threads for them.

If you use the search function you'll also find another build thread for this type of bike (and some other discussion about it, though those others are probably not relevant to your build).


I would also recommend keeping all of your project in a single thread, so the people already helping you can keep doing so, instead of having to find each new thread you make for it to continue helping you.

It also is helpful for anyone new coming upon your later questions to not then ahve to dig thru the forum to find your original thread/questions to get all the info needed to help you with the latest one.

 

[dogman dan]

I have found using wood and aluminum sheet easy to work with. Thin boards for ends, bottom, etc, then screws easily go into the wood to secure the aluminum sides. Variations abound, plastic, paneling, etc can be the sides. My best results started with knot free, tight grain poplar boards, 1/2 thick rather than cheap pine 1x4.

Also don't overlook the possibility of a bag. such as a camera bag, to fit that space. Possibly supported by a board or metal plate attached to the frame.

 

[ebent]

I used 1/2" starboard. It is used in the marine industry a lot. It has advantages and limitations. It will saw, plane, drill and hold screws if given the proper pilot hole. It will not sand, paint or glue. The stuff is very tough. Waterproof. I think your idea of behind the seat is the best choice. Good luck.

 

[bowhunter29]

I would encourage you to try KYDEX. It's a very durable material and can be ordered in some pretty thick sheets. I ordered a couple sheets (see link) for my Luna/LR build in order to fab some motor covers for it. Not sure if I'll need them but it can't hurt to have them in stock .

http://www.knifekits.com/vcom/product_info.php?cPath=41_54_136_653_688&products_id=5854

jeremy

 

[craneplaneguy]

Kydex is often used in the home built aircraft world for inside the cockpit uses. It can be brake formed I understand. As can Lexan.

 

[spinningmagnets]

I'd start with plywood, fast and cheap. Once you are happy with the size and shape, you can consider other options for the second version...

 

[judson]

Great! That gives me some interesting new materials to check out. I found the 'Show us your battery housing' thread just after I posted this question. Looking through that thread gave me a few ideas but most of those where either rack top boxes or inside the triangle. Anyways, I appreciate the help. I will look for the build thread about this type bike, though I already did search for 'sun atlas cargo' with very limited results. That said I am far from an expert at searching this site, seems like I never know which sub thread to search, Battery Technology, Ebike General etc.

Thanks all!!

 

[LI-ghtcycle]

Two other possibilities, the other could entail adding a front cargo rack of this type:

 

[cwah]

why not the triangle?

 

[judson]

[/url]

Yeah I had actually considered this lower placement. There are in fact two braze ons there for mounting a bottle. My concerns were, first that the braze ons might fail if I say hit a pot hole or something like that. To combat this I was thinking of pipe clamps around the frame and battery (or perhaps just the frame and battery mounting system). This could possibly make battery removal much harder. My second concern with this spot is the water off the front wheel. I live in Seattle after all. That said, I have very substantial fenders on this bike already. I am still in the early stages of researching waterproofing so not sure how worried I need to be on that front. All this said, this would be great for lowering the center of gravity. Another pro is that I could use a standard bottle type battery and not have to fabricate a case myself.

Above the top tube is likely out. I don't want to complicate the step over for dismounting. That is already precarious enough with passengers on the back.

 

[LI-ghtcycle]

Yeah I know what you mean, I live in Oregon City, OR so we get a bit of rain too!

My father rides every day rain or shine and he has a "water bottle" style battery, and it has never been an issue.

This is what I would buy if I wanted that style, not sure if it would fit in the back inside the frame near your passengers?

http://lunacycle.com/batteries/packs/48v/48v-panasonic-11-5ah-or-13-5ah-bottle-battery-with-charger/