how much impact can eBay type lithiums take?

[SniperGaulois]

If you put a duct tape battery in a very tight metal box and fill all the gaps with paper and a tiny bit of padding on top of the soldering connections, And then strap it on to a bike and jump around the hills a lot, it should survive pretty well no?

 

[Link]

That should work fine. But paper? Little ghetto. Use some sort of foam padding. It will hold it in place better and not shift around like paper would.

 

[SniperGaulois]

Thing is I have made a box which has literally 3 mm extra space in which to cram something spongy so I couldn't think of anything, although the idea is to have some polystyrene on either side in case it falls over onto some rocks. the idea is to have it wedged up really strong to the seatpost with a bit of cloth to help dampen vibrations from the bike. check it out I recycled my PC case by folding it over the edge of some stone bricks and hammering the corners, 1 mm aluminium can make some really easy crafting as long as there is only one layer to fold or else it goes round, which I found out on my first attempt.

 

[Jozzer]

Coroplast (corrugated plastic, comes by many names) is thin, and i've found it to be very resiliant used in this application. Usually 3 mm thick, can take a bit of compression though..

 

[Ypedal]

Oh man.. I like to think i've tried it all.. but i keep finding better and better materials as i go..

Tool Box Liner - Comes in roles, spongy rubber, perforated, same as i used on the inside of my lexan boxes, 1/8th thick and it will not compress.. it stays spongy.. Also found in department stores for kitchen drawer ( sp? ) liners..

Crazy Carpet - Kits plastic sled sheets, you roll it out. sit on it and slide down snow hills.. dollar store..wall mart.. toys R Us

Foam in a Can - tricky.. but you can spray it into a box. let it harden and then cut it with a bread knife..

Door Mats !! ( seriously ! )

Peel and stick flooring tiles !!!

 

[andrew]

Maybe used bicycle or motorcycle tubes? I used these to cushion my motorcycle batteries. They can be mounted in solid, and don't move or bounce around at all with some give for battery expansion.

Though they may help start a fire in case of a short causing a lot of heat.

 

[albie]

i think i've been pretty rugged with my pack...

I've had mine just sitting in the duct tape that comes with it housed in a topeak bag.

had a couple of nasty drops (ie dropped off my table... came off the topeak clip at like 50km/h).

Also survived the bike accident i had a couple of weeks ago.

I've killed 2 cells on the thing since i've got it cause i've been pushing the thing to see where it would break (ie 35a - 39a constant + insane 30*C heat)

 

[SniperGaulois]

came off the topeak clip at like 50km/h

Oh goodness me-that was lucky, I fell in a pond the other day-it was in the dark and there was this unexpected pit of pure sludge on the side of of the track that threw me about 5m into a puddle bigger than my bath tub.! Fortunately I left the bike far behind me.
I reckon if it falls on a corner a couple of times some of the cells will be pretty messed up. and when the bike topples over on its side on some rocks.

 

[kbarrett]

I would suggest a slightly larger container + cut up closed cell sleeping pad.

 

[SniperGaulois]

I did, I trashed the aluminium case, it took me ages to make but it was touching the back wheel and I've got a really good cheap seatpost rack where you can adjust the length of the flat platform relative to the bar, and I found some strong material and sowed up a bag which fits one half of the battery on either side it's brilliant! It's just perfect, really easy to unmount, just have to make some shielding for side impacts.

Closed cell sleeping bag material sounds interesting will have to look it up.

 

[kbarrett]

Closed cell sleeping bag material sounds interesting will have to look it up.

Pad ... not bag.

http://www.rei.com/REI-Outlet/product/767132

The closed cell stuff is pretty cheap, doesn't soak up water, and makes good insulation on cold days.