Rain proofing your ebike - whos riding in the rain ?

[montyp]

I don't mean to press on this, let me know if this is getting annoying. I'm just curious how this is happening.
...

The current on a narrow wire should only increase the temperature, which I assume is not going to be much different than being close to running engine. If it is higher, you are probably seeing solder reflowing.

If the wire is corroding, the corrosion is probably due to flux or the brine reacting with the flux. What kind of flux are you using? Might want to consider using a different flux cleaner too.

 

[MadRhino]

Well, wires do heat, and winter is cold. Alternance between very cold and hot loosen the water protection and let the salted water in sooner or later. The flux is also making the wire easier to corrode of course, and melting agents that are used in the city may be worse than plain salt for corrosion. The fact is, that after riding the whole winter (about 4000 Km), I find all connections are better to be refreshed than waiting for bad contacts to happen during the summer.

 

[brumbrum]

If anyone uses a frame battery bag, or any other bag for that matter and is worried about water getting in through the stitched seams.... Turn the bag inside out and paint between the seams with old fashioned copydex glue. It is made to stick to fabric, it dries to a rubbery flexible skin, and its washable and waterproof.

 

[cal3thousand]

I'm surprised you have to replace all the connectors every 2 years. Cars basically have the same exposure as ebikes with about 50 times more connectors and maybe the first connector will fail at about 10 years.

Winter prep is typically not too hard, a little coverage (bags, fenders, etc), some electrolytic gel and the bike is good to go.

Cars DO NOT have the same exposure as bikes, with respect to the connectors. Cars have an engine bay with splash guards and seals while ebikes are generally left in the open. And even though moist air can move through to the engine bay, car motors heat up very often, evaporating residual moisture. Lastly, car connectors (at least the ones in my car) are mostly waterproof. They have rubber seals preventing water ingress from both mating and wire exit sides. When rain drops from the sky, a car's connectors are in no danger of getting wet. With an ebike, water will find it's way into anything that is not properly sealed.

So I'm not at all surprised that MadRhino replaces his connectors every season or two. (He also rides a TON and in nearly any weather)

 

[Tom L]

I wrap all my connectors in self amalgamating tape like Scotch 23. It forms a solid rubber mass that is water resistant. The grey Scotch 70 silicone version is also good for extreme temperature environments.

It can be a little tricky sealing the junction of multiple parallel wires. The secret is to wrap each wire individually then the whole bunch. The individual wraps are squeezed together to seal the gaps between the cylindrical wires.

It can be removed with a pocket knife.

Edit: here's an example of it being used to waterproof an outdoor RJ45 security camera connector: https://youtu.be/fJPOYCDH8wE?t=1m58s

I would suggest at least two wraps of amalgamating tape and a layer of good quality stretchy electrical tape over the top (Nitto or Scotch 33+) especially if you are going to be riding through lots of standing water or if you hose your bike down.

You can build up parts of the connector that have widely varying diameters with a similar product that is thicker (commonly called mastic tape or insulation putty). Then wrap with the amalgamating tape.

 

[hydro-one]

I ride a very high powered bike similar to madrhino and in a similar manner . I ride all winter here in winnipeg and ypedals suggestion of hosing down the bike is very good. the salt will find its way into your wiring and especially the throttle wires. bundle the signal wire (green) and the ground together at connectior bundles, and the 5 volt positive wire keep it separate. so that when salt gets in there with water it dosent take off on you . which used to happen to me occationally usually resulting in a funky form of scary cruise control when in slushy brown sugar, wet snow ,full city traffic, 1 feet from cars also going 50 60kmh. the trottle itself is prone to salt water ingress also at the hall legs you can pour epoxy to solve this. the suggestion of
self healing silicone tape is good and works well. easy to remove if needed and flexible . liquid electrical tape stinks and messy, hardens and is impossible to take off and wires also crack at the interface due to stiffness. it is pure garbage. and i have a controller that needs totally rebuilding the wires due to treatment with this crap.

motor , i have not had any issues i just took apart my cromotor after two winters and it is only slightly rusty near the magnets and back iron..water cannot last in there at those tempertures. it is driven out pretty fast if it gets there at all which i doubt bastd on the condition.

batterys , dont get hobbyking packs wet they will corrode at the cell tab and be useless. especially nanptechs . nanos have foam there( and other shoddy work) to help hold the water and corrosive salt or whatnot so they will be ruined in short order esp if you are using the pack alot. mine are done after 3 months.....thanks hk . persoanlly i reccomend hardpacks in backpack had no issues with plastic bag on them .

controller itself i feel that it is well eough sealed (kelly non waterproof) for normal water spray but im carefull when i wash with pressure washer. infinion can get water in them easier and then i take off plate and wash out with isoproypyl 99 percent happened mabye 10 times in my life . that fixes water issues on any electronics btw.

rubber glove or plastic baggie on throttle would be a good idea if unmodified cheap throttle is used in rain and ive often taped a plastic bag over my controler and wiring in emergencys (when it rains lots )

hydro freerider 30s cromot


edit i have heard of someone here using sections of rubber innertube and putting wires though it where connectors are and zip tieing around each end . this works great and is cheap.

 

[greggw]

I had built a Bafang BB02 during the winter to ride the beautiful trails In Gulf Shores Alabama.
I used a Mongoose 27in mountain bike for the project. The build went easy enough except for a few minor
problems with the bike itself...my next bike will be shorter beach cruiser.
I had ridden the bike for approx 15 miles for testing and adjustment before taking it on our beach vacation in early May.
The bike performed very well except for the chincy brakes used on the mongoose...
I had stored our bikes bikes in the back of the truck using side rail clamps for easy transporting .
We had gotten caught in a flash thunderstorm and I had to drive several miles before we could find a gas station with an awning
so I could recover the bikes to keep the rain out of the electronics.
Well the Sondors bike weathered the rain perfectly...the Bafang BB02 not so well.
After we got home from the trip I tried troubleshooting the Bafang's failure with Lunacycle's tech support which was somewhat helpful.
They walked me through several attempts to bypass the display to see if I could test the motor without success.
I am very disappointed with the Bafangs lack of waterproofing the controller. When I removed the unit from the motor it
was wet to touch and actually has water trapped inside the "waterproof" housing. Needless to say I now have to replace a 100 dollar controller
That was waterproofed from the factory.
As I look forward I will be trying these waterproofing ideas out I read about on this site.

 

[cwah]

Are the higo s connectors good for throttle?