E-bike + carbon frame + 52V. 18650 + BMC motor

[soaresdacosta]

Hi guys,

Between some small drives, I need to finish my battery layout.
For me to put all the battery in a compact spot, inside the box...I need some changes... I need to take-out some of the vinyl, cut some parts, change the switch for my temperature-meter (small one), put the vinyl again...just because some centimeters.
But its ok now. Now I can put all the 8 lipos together, and I have space to upgrade to 15amps.
Its time to make the parallel connections and the final layout.

Luis.

 

[soaresdacosta]

...the work continues in my battery layout.
I'm building a protection in acrylic for my battery. Its more easy to put in, and take out...so I start to learn, how to bend acrylic. A first test, and the result is very acceptable.
You can see the idea.

Luis.

 

[soaresdacosta]

...the final push continues.
Yesterday, after some training on bending acrylic...its time to bend the box.
I believe this is the better approach. I'm going to use pp45 to pass from parallel to series and some bullet stile connector for the controller.
The pp45, going to be installed on the face of this box. For the balance wires, I'm going to use a DB37 connector.
Wen I want to ride, I take my battery box from my "bunker", install in the bike, attache my pp45 block...

Luis.

 

[soaresdacosta]

Working on this final task...
I want to have an easy way to charge. I can charge the 4 sub-packs individually or I can charge all at the same time in parallel.
I have a lot of wires to solder, and want to be very cautions.
To be continued...

Luis.

 

[soaresdacosta]

Not much done...Life got in the way.
just some work on my battery, opening the holes for my pp45 and my DB37.

Luis.

 

[soaresdacosta]

...continues to 100% finish.
Still working on battery layout. Everything is thought, I just need to make it.

Luis.

 

[Emoto]

...continues to 100% finish.
Still working on battery layout. Everything is thought, I just need to make it.
Luis.

Luis how long till you finish

 

[soaresdacosta]

Hi Emoto,

...well...almost finish...

I'm just finishing my battery layout. Soldering the parallel connections, and the balance wires to the DB15. And soldering the wires on the charger side.
Wen I put the battery on the bike, I have 4 packs of 6s 10amps. Then I change to 24s 10amps, wen I connect the andersen connector block. To charge, I can charge each 6s 10amps individually or I can charge all the 4 packs in parallel, at the same time...the charger have power for that.
I want a "noob" proof charging system. And I want to charge and store my battery in my "bunker".

Take care,
Luis.

 

[soaresdacosta]

The work continues on the box inside the box... :lol: :lol:
Since I like "carbon look", I cant live this box alone... cant I ???

Luis.

 

[soaresdacosta]

...one more step closer...

 

[soaresdacosta]

The "looks" of the box-inside-the-box, is finish. Everything test fitted, and so far so good. All the gaps are ok.
Now its time to assembly permanently and definitely the batterys in to the box, and start to ride more often.
I need to put some "Velcro-stile" to secure my "Magicshine" light battery.

Luis.

 

[soaresdacosta]

Hi guys,

Long time waiting for some parts...cables and small stuff.
Its time to make the permanent connections on the battery. I choose to crimp the cables for the parallel connection, instead of soldering.
Wen I was trying to put a 10g cable on a anderssen pp45, without the proper tool, I send a couple of them to the trash. Then I decide to buy the tool from "powerwerx", and Its so easy now. Wen we have the correct tool for the job...

Luis.

 

[markw]

Happy New Year!

Such patience with this build. Can't wait for the end product - all the work will be worth it on this bike... I love your commitment to nothing but the most simple and user friendly end result. Gonna have to get me some of that carbon fiber stuff. Thank you so much for taking great pictures and sharing all the steps along the way.

Cheers!

 

[soaresdacosta]

Hi Mark,

Thanks for the kind words.
A lot of work and patient, but I like the end result...especialy the performance. This motor is incredible...its eavy but a lot of power.
And I try to build a good looking bike too. Its time to enjoy 100% of this bike...almost finish.

Happy 2015
Luís.

 

[soaresdacosta]

Hi guys,

Since I was not happy with the bullets connectors, I need to change hall of them. Maybe its my soldering station...maybe its the guy soldering... :lol:
I go with Andersen 45 amp, and since I have the crimping tool, the job was easy.

Luis.

 

[soaresdacosta]

Since I change the bullets connectors, I need to redone all the parallel cables, with the new anderssen connectors.
In the meantime, I collect parts for my "lipo charging station"...that will be the last thing on this build.

Luis.

 

[cwah]

nice job, very neat

how much did you invest in crimping equipment?

 

[soaresdacosta]

I cwah,

Thanks. For the "Anderseen" I buy the "real" tool. Around 75$ with shipping to Portugal. The Hydraulic, I buy on E-Bay, 150$ with shipping.
I found out very fast, that you need the right tools, to make the right job.

Luis.

 

[lukii]

hi
What material did you inbox . Is this the plexiglass ? What is the material thickness ?

 

[soaresdacosta]

Hi lukii,

The "box-inside-the-box" is 2.5mm acrylic.

Luís.

 

[lukii]

Thank
Tell me what is the thickness of the outer Plexiglas box?

lukii

 

[davidraaymakers]

Such a shame I did not see this built earlier..
That a side a beautiful build bike!
May i ask where you bought your rivet nuts

Thanks in advance,
David Raaijmakers

 

[soaresdacosta]

Hi lukii,

Its ok. Glad I can help.
The outer box is 5mm.

David, I buy the riv-nuts in a tool house...you can buy them on ebay...and the tool to install them.

Luís.

 

[atomek1000]

Very amazing attention to detail!! Good work, inspired me to do simmilar battery box I must say looking at this box and amount of that carbon tape your house is probably covered with carbon too :lol:

 

[soaresdacosta]

Hi atomek1000,
Thanks, glad I inspired someone. The battery box, was not difficult to make, just very time consuming.
Take care,

Luis.