Show Us Your Homemade Battery Housing

[Hyena]

The stuff I use is used for guttering down pipe and is 100x55 or 100x65
It's a slightly tight fit for anything other than the thin 6S zippy lipos but I find cutting a slot in the bottom solves the problem. It has to sit on the bar of the bike anyway so with a stainless steel clamp front and back it's held down tight. Mind you the bike I have this on uses a top bar with a flat tube, which I then bolt L brackets to to further support the box (it can slip slightly with round tubes but you need to be giving it a hiding and landing jumps etc)

 

[migueralliart]

Made from 3/16" thick ABS

And installed housing 2 5000mAh 6S bricks, I could've made it thicker too accomodate 4 but I really like how it looks this way.

Only the left side opens with 2 bolts, so far it is pretty rigid.

 

[ddk]

not so much as home-built as re-purposed.

 

[d8veh]

 

[Tommy L]

Here's my repurposed fuel can!

Ok...... Now this takes the CAKE! Well done! LMAO!

Tommy L sends... \\m//

 

[litespeed]

Excellent looking battery box. My first one for my Giant Reign will be wood also. Maybe after all the bugs are worked out I'll try my hand at some fiberglass....How about a full view bike pictures?

Tom

 

[oatnet]

Beachcruzer did a nice job with a pelican 1200 case, fitting 24s2p lipo into a hard-mounted front case. This is 1kw of improved handling. More pics here:
http://www.endless-sphere.com/forums/viewtopic.php?f=3&t=37759&start=45#p634997

 

[Xanda2260]

Here's my repurposed fuel can!

Ok...... Now this takes the CAKE! Well done! LMAO!

Tommy L sends... \\m//

Glad you like it

 

[spinningmagnets]

From Qwiksand, four LiPo 5S bricks, 10S / 10-Ah:
http://endless-sphere.com/forums/viewtopic.php?f=6&t=45259#p659599

 

[shock]

.063 Fabricated aluminum case. Attaches via velcro on top of a .125" aluminum bar bolted to the water bottle mounts. Uses velcro straps all around to secure, yet makes removal easy.

 

[fluid2150]

Well, heres my setup people. Loving this ebike thing.
i just made the 50kms club. LOVE IT!!!
its a giant glory 01 (electric glory) im coining that phrase
t has a 9c 2810, 48v 10amp headway pack (upgraded)
to 72 now) and a lyen controller. He is a gun!!! much
appreciated lyen! goes like a rocket. pulling max 50amps
at 115 throttle. can you go 120? im sure some smart cookie
might know. well all the best people and hope it gives
you some ideas. ebikes!!!!!!!

 

[spinningmagnets]

From e-cannon: fiberglass over styrofoam, then cut out styro, bondo/paint...very professional!

http://endless-sphere.com/forums/viewtopic.php?f=6&t=13411

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An almost identical DIY battery box from davy1010:
http://endless-sphere.com/forums/viewtopic.php?f=2&t=24382

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repost from earlier in the thread because these three are so similar:

From dannyboyohyeah, using PVC pipe for the rounded edge, wood everywhere else, and fiberglas over it all, Beautiful result, easy to do!
http://endless-sphere.com/forums/viewtopic.php?f=28&t=30457

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From E-Norco
http://endless-sphere.com/forums/viewtopic.php?f=28&t=49570&start=25#p791604
http://endless-sphere.com/forums/download/file.php?id=119347

 

[atom1025]

Here's what I've been working on for the past 3 weeks.

Almost ready for paint. Can't decide if I'm gonna rattle can it or have the autobody shop across the street shoot some paint for me. Getting a quote tomorrow.

I still have not figured out how to uploads pics but I made a stupid photo bucket.

http://s1322.photobucket.com/albums/u577/atom1025/Cannondale/

I had a revalate bag on it for a while now. My lipos went south and I can't afford new ones till tax time. I had a bunch of composite making stuff gathering dust and lots of time so I ventured to make a bad ass ride.

Used 1.5" foam. Covered with bondo. Used yellow glass mesh like a chicken wire. More bondo. Followed by 3 layers of the heaviest s-glass Taps plastics had to offer.

Its powered by a mac10 at 57v. Bout 30mph and peaks about 2000w.

 

[potatorage]

This holds a 52v 9.2ah a123 cellman battery. The side strap opens on a hinge for easy and secure battery removal. I need to add a metal loop that I can hook my ulock through for real security.

Cost about $13 and weighs <2lbs. No welding, just counter sunk the screw heads where necessary.

What kind of metal did you use? And where did you get it so cheaply?

 

[veloman]

This holds a 52v 9.2ah a123 cellman battery. The side strap opens on a hinge for easy and secure battery removal. I need to add a metal loop that I can hook my ulock through for real security.

Cost about $13 and weighs <2lbs. No welding, just counter sunk the screw heads where necessary.

What kind of metal did you use? And where did you get it so cheaply?

They are easily found in Home Depot (or Lowes). It's galvanized steel, so no rust. About $1-4 for each 'strap'. Look in the lumber section. Much cheaper than the metal stock section. Bend very nicely. It's meant to tie lumbar end-to-end I believe.

 

[spinningmagnets]

from nonlineartom...bent sheet metal, U-bolts

http://endless-sphere.com/forums/viewtopic.php?f=6&t=40537

 

[spinningmagnets]

From Dreddydave
http://endless-sphere.com/forums/viewtopic.php?f=7&t=44860#p653370

 

[givitago]

Folded aluminum sheet, pop riveted together and countersunk on the interior. S/S piano hinge lid with a toe clip strap to hold it shut. I'm using nylon straps to hold it on and together with the flanges (inner tube backed), it makes for fairly quick mounting and removal. A small spacer holds it forward for a tight fit into the triangle and to hold it off the rear shock. It has been well weather and crash tested now and seems to be holding up well.

 

[schmidty_81]

.50 Cal Ammo Tin.

 

[spinningmagnets]

I'm going to use this post as a Pelican-case front-basket mount index:

pendragon8000: http://endless-sphere.com/forums/viewtopic.php?f=1&t=49136&start=300#p783087
oatnet_______: http://endless-sphere.com/forums/viewtopic.php?f=3&t=12847&start=200#p443883
Beachcruzer__: http://www.endless-sphere.com/forums/viewtopic.php?f=3&t=37759&start=45#p634997

From Racer_X, some parts of the design are from ions82 build...
http://endless-sphere.com/forums/viewtopic.php?f=6&t=46518#p680407

 

[ions82]

I tried to take a few better pictures of my battery housing. When I started out with this build, I knew that I wanted to use a Pelican case for the batteries. At first, I was thinking that I would mount it in the frame. However, after seeing Oatnet's front-mount setup, I thought it might be a good option for mine. Fortunately, the Electra has an extra-long headtube that is perfect for clamping to. The difference in handling that it makes is astounding. Even before I electrified this bike, the front end didn't feel all that solid when cornering at speed. Now, I'll take turns at 20 mph. It feels like it's on rails. Having the pack mounted to the frame is nice, because I don't feel the additional weight in the steering. It's all in the handling.

I also took a few pictures of the battery pack when it's dismounted. The extra holes in the nylon plate are for vertical adjustability. I figured it wouldn't hurt to have those in case I needed a little more clearance above or below (for cables, lights, and such.) The modular setup is very handy and very secure. The pins have a snug fit, and you have to make sure that the pack is going on square (or it won't slide in place). It has a bit of a "friction fit" that doesn't allow anything to rattle around. I could probably leave the safety latches undone and never have it come off (but better safe than sorry.)

The inside of the case is padded, and the batteries fit in quite snug. When I charge, I check each pack with the CellLog before parallel balance charging. It takes a little extra time to handle all of those connectors, but I figure that an ounce of prevention... Being able to take the pack off the bike gives me a bit more peace of mind, and it is quite convenient for safe charging. If anyone is in the market for a new bike to build, I would highly recommend an Electra Townie. They handle great at speed, and the frame design is very comfortable and spacious. While riding, I never feel like the ride is too rough. I'm having too much fun leaning the bike into turns and giving it throttle on the way out!

 

[ebent]

Nice work! Looks solid and secure. Where did you get the clamps that attaches the nylon plate to the bike? Or did you make them?

Thanks

 

[ions82]

Nice work! Looks solid and secure. Where did you get the clamps that attaches the nylon plate to the bike? Or did you make them?

Thanks

I machined the clamps myself. I was thinking about making a couple extras as it is pretty easy to do multiples once everything is set up. However, I figured that there wouldn't be too many other people that would be doing this same setup. Not many bikes have a super-long head tube like this Townie does. I will soon have CNC capabilities in my shop, too. So, future parts will be even more polished and refined. I'd love to make custom e-bike parts for others. It is a joy to ride this bike, and I'd like to help others get the most out of e-bikes, too. I sure am glad that ES is around. It's a fantastic community.

 

[spinningmagnets]

From flyinmonkie in New Zealand

http://endless-sphere.com/forums/viewtopic.php?f=28&t=19841&start=165#p403510

 

[contador]

Hi,
This is a leather bag for a 36v-10ah Ping