Show Us Your Homemade Battery Housing

[Tony01]

1980 Schwinn Cruiser.. 23kw 72v 60ah... Fiberglass on foam core.. fully fabbed behind the seat tube..

 

[larsb]

Ultra clean build there :thumb:

 

[markz]

That's right, make them look like sticks of dynamite. . .

And place it on a motorcycle looking bicycle.


I was on the train the other day, and had a convo with a person sitting next to me. He said a usual question, is that an ebike, but asked another question thats never been asked before: did I gerry rig my bicycle, I was a bit taken back, and a bit offended then went into the usual talk of how they come in kits and you just really solder 8 wires together, or get plug and play. Luckily the fella got off at the next station so I could get back to my tunes before I was rudely interupted. They see my headphones, they have white wires against dark clothing which is noticable yet people still want to interupt my relaxing mode.


My last incarnation, to lazy to find the current fat bike setup pic but its the same.

 

[RootedSuperuser]

100% Aluminium, TIG welded, with 3x T6 Titanium screws.

Make a template from poster board.

Cut the aluminium.

Shape the aluminium.

Checking the fit prior to TIG welding.

Checking the fit prior to TIG welding.

14*6 TESLA 18650 cells.

Finished ride.

And for the WIN!

 

[Monte]

3D printed perimeter. CNC router machined acrylic sides. Attached with m2,5x6 plastofast screws.

Waterproofing with gasket tape. Fully waterproof under faucet. One drop got in when submerged. The BMS's power switch is under a rubber shielding and the charge port is accessible via a M12 gore-tex valve screw, which also allows water vapor to exit the pack.

Battery sits on top of controller box and is attached with stainless steel latches.

Pack is 14S4P Samsung 25R's with a generic Chinese BMS that seems to work well.

 

[weng]

New here mostly lurking

Here's my homemade 13s6p battery on a Kona DH bike. The pack is composed of re-purposed laptop cells rated at 2100-2300 mAh. Also, installed an active balance to balance the cells while the pack is not in use.

 

[greenspark]

Army surplus with zip ties
Saddle leather - homemade

 

[PeterpDahl]

13s3p (21700) in a 3d printed casing, 30A BMS.

 

[rowbiker]

Love the matched pumpkin colored filament -- very nice touch (or painted?)

Cells connected via spot welding?

 

[PeterpDahl]

Love the matched pumpkin colored filament -- very nice touch (or painted?)

Cells connected via spot welding?

Lol the casing is not the final one - I’m printing in a color that matches the frame better. Yes, spot welded, I’ll try to find a picture of it

 

[PeterpDahl]

 

[rowbiker]

Nice and neat! I like the symmetry of your 'penta' spot weld pattern, plus the welds look great. Which spot welder did you use for this?

 

[PeterpDahl]

Nice and neat! I like the symmetry of your 'penta' spot weld pattern, plus the welds look great. Which spot welder did you use for this?

Thanks

Dunno, I did not weld it myself - it is the same guy I have used before. Always top quality work from him

 

[brownj24]

Is your guy in Canada by chance?

 

[mercly]

What type of filament you used for that?

 

[PeterpDahl]

What type of filament you used for that?

That one is made in PLA - it was a prototype.. Current version is on copper PLA - but once summer hits again I'll make a new one in ASA.

 

[armandd]

My lipo battery box, made from plywood and aluminium angles. Not painted yet.

 

[spinningmagnets]

Built by Adam Livingston. Details in the link.

https://www.electricbike.com/adams-black-panther-with-bbshd-ludicrous-v2-3-speed-and-gates-drive/

 

[nicobie]

That's pretty slick. I like the way the tank and battery box look on the bike. Nice lines.

 

[markz]

:thumb:
Sure thing, I do agree on that and its black on black on black and it all kinda hides the mid drive motor :thumb:
Waaaaaaaaaaaaay better then any store bought ebike!

I scanned the article and couldnt find the battery size, I'd want a decent size battery in there in terms of Wh.

That's pretty slick. I like the way the tank and battery box look on the bike. Nice lines.

 

[spinningmagnets]

52V and 17-Ah

It also has a socket that allows a Luna Wolf to be plugged-in...

 

[ccihon]

I have been using an inexpensive "tool bag" from Harbor Freight, though this is like may other 11" military surplus canvas bags available. It has a rigid bottom and a small snap-closure side pouch. I have a 48V 22ah pack battery in there, plus a little room on top of the battery for a tool pouch I carry. This is mounted to a T-Cycle battery mount - I wanted a quick-release sort of attachment rather than fishing the pack out of the bag when needed, so I used some photo-intended parts I had - an arca-style quick release plate and long clamp. These bolted easily to the T-Cycle battery plate and mount, and the plate is attached to the rigid bottom of the bag. I actually tried a 50-cal plastic ammo box, which fit fairly well, but was oversized and didn't look quite as stealth as the bag.

 

[99t4]

That's a great ingenious idea!

Just curious: What's that IEC plug there in the 4th photo?

 

[markz]

That's a great ingenious idea!

Just curious: What's that IEC plug there in the 4th photo?

99t4 - Perhaps for a charger.
ccihon - If so, is the charger stored in the housing when you ride around for guerilla charging?

End sockets come in various shapes.
Grintech's Satiator is IEC C14 on the Satiator itself and you use a Universal Power Cord 90 degree elbow IEC320 C13 socket (plugged into the Satiator) to NEMA 5-15PC13 (to plug into it to the wall power outlet.) cable.
Plug could be any variety depending on country voltage used.
https://www.mcmaster.com/iec-cords/

Some of my other chargers use IEC C7 / NEMA and charge at 8A, Meanwell HRP charger was just wires to screw terminals in+out with NEMA 5-15 for wall outlet. Next is MW RSP-1000 for 13S @ 43 ~ 55V and 21A. Have to start finding 2 outlets on separate circuits close together to keep a close eye on them when I am guerilla charging. Ice chest outlet or pop machine outlet and regular outlet (Walmarts or gas stations). Get 2.3kw of juice in an hour for 82km/51mi riding distance. (28wh/km is 48wh/mi.)

 

[john61ct]

I have been using an inexpensive "tool bag" from Harbor Freight

Excellent, stealth, and fast removability is great for safety as well as anti-theft in sketchy areas.