Show Us Your Homemade Battery Housing

[amberwolf]

#2.) Think rear rack mounted Jackobs ladder

Find a way to insulate the spokes from the rim and hub, and run alternating polarities to every other one. A whole WHEEL full of Jacob's Ladders! (yeah, I know it wouldn't work, but the IDEA is cool!)

 

[AussieJester]

:: backs away slowly not making any sudden movements and avoiding direct eye contact with mwkeefer OR amberwolf :: LOL

KiM

 

[NeezyDeezy]

What is that black cable housing coming out of the pannier? I like the way it neatens things up. I'd very much like to get some for my ebike. Can you link me to what it is and where I can get it?

Thanks,
Nate

 

[amberwolf]

It looks like the same stuff they use to cover automotive wiring harnesses, which is a lengthwise-split corrugated plastic hose. If so, it's probably available at any of your local car parts places.

 

[NeezyDeezy]

It looks like the same stuff they use to cover automotive wiring harnesses, which is a lengthwise-split corrugated plastic hose. If so, it's probably available at any of your local car parts places.

Good call, even if that's not what's in the picture, it's what I was looking for, I just didn't know its name. Thanks again amberwolf.

 

[mwkeefer]

Aussie,

If you do the jacobs ladder, i suppose it would have to be called 'Stunning' - (I just couldn't resist)

There's a new anti-theft measure, stun gun with probes mounted between the seat and the bars, instant theft repellent.

-mike

 

[docnjoj]

Um...............I guess you better not forget to turn it off!
otherDoc

 

[e-cannon]

It's been a couple of weeks ago... but this would have been the right thread...

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

@AussieJester: Nice work. I like the condenser thing. Reminds me of some racing cars. And you were really fast... And I am a bit jealous of your workshop. Will you bake your box before painting?

 

[AussieJester]

It's been a couple of weeks ago... but this would have been the right thread...

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

@AussieJester: Nice work. I like the condenser thing. Reminds me of some racing cars. And you were really fast... And I am a bit jealous of your workshop. Will you bake your box before painting?

Nope no baking required matey its fully cured in above pics... be painting it as is...well after a few more coast of spray putty and rub downs with 800 wet and dry

Cheers

KiM

p.s nice work on your battery box too is the best example i have seen on a MTB without doubt.

 

[lynchy]

AussieJester,

I read the whole thread on your bike build on the Ratbike forum you linked to previously. You're doing a great job there. It's great to see someone that has had a bit of a nasty accident like you did, but goes on regardless doing what you love. Fair play to you :wink:

Had a nasty accident myself on a sports bike about 2 years ago, not long after passing my test. Had pretty much a full head on into an oncoming car when I ran wide on a bend. Luckily I didn't hit it bang in the centre but hit the wing, was thrown down the road an didn't catch any trees or other vehicles on the way.

Was doing at least 110kph, don't know what they were doing :| By some miracle I escaped with just a compression fractre on my right lower leg below the knee and was on sticks for a couple of months and a few more months physio. Back on a new sportsbike, the day I got the OK to start walking Well you've gotta haven't you

 

[AussieJester]

Sheeesh man your lucky you weren't written off, head on with anything on a motorbike uuuusually never ends well for the bike rider...

KiM

 

[lynchy]

I know mate. Not many people get away with what I did that day. The guy following me saw the impact and said eveything just exploded off the bike. It was a fully faired ZX6R G1. He was sure I was a gonna. Someone's looking out for me for sure.

Sometimes it takes something like that to make you realise what lifes about and my life has changed a lot since then and all for the better. Starting a new business now (selling e bikes and e bike kits, if anyones interested :wink and now living in China with a beautiful youg lady that I hope to marry

Life's what you make of it and as far as I know we don't get a 2nd chance, so best make the best of it while we're here

If's there's anything that you're looking for over these ways, give me a shout and I'll do my best for you. Can always get a sample or 2 sorted :wink:

All the best
Lynchy

 

[adrian_sm]

Just modified my battery housing. Here are some pics. Trying to go for a stealth type look.

And this is the what the structural sheet metal inside looked like, before I put the new bag around it.

More details in my build thread if you want them.

Cheers,
Adrian

 

[StridaHope]

Mine is nowhere cool as you guys', but I found that the duct tape battery pack I got fit almost EXACTLY into a 200CD hardcase from Atlantic. All I had to do was rip out the rack parts from the inside and cut out holes for the power and charging ports. The upper rail in the lid of the bike had just enough room to house the BMS securely, and when I flip the case lid open the BMS and battery are both easily accessed. Here's pics with the battery on the bike (redoing the cabling in the pic so this is NOT the final product). Obviously the factory CD case sticker will come off at some point and get replaced with much more interesting decoration. =)

Incidentally, and not battery-case-related, I made my own torque arms for it. The torque arms look janky, but they actually work well because the bolt holes in the two pieces of metal draw arcs that only intersect at one point.

View attachment 2

 

[Solar Motion]

Liking the case StridaHope. Makes transporting for charging really easy. Did somthing similar with a case from Harbor Freight. Fits the controller as well.

It was on sale local for $10. http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=36870

 

[nicobie]

What is that black cable housing coming out of the pannier? I like the way it neatens things up. I'd very much like to get some for my ebike. Can you link me to what it is and where I can get it?

Thanks,
Nate

Hi Nate,

I didn't notice your post.

It's called cohesive flexible bandage. It can be bought from any veterinary supply outfit. It comes in a lot of colors and widths and costs about $1 for the 4"roll. I also used it to wrap the top tube on my bike to hide the wires. The stuff works great.

http://www.jefferspet.com/ssc/product.asp?CID=0&pf_id=0029430

 

[crichman]

Here's another stealthy approach, this one for a Bionx pack hanging beneath a Bacchetta 'bent main tube. The cover is sewn from light-weight cordura, has a port with a flap secured by Velcro for charging, and a zipper across the bottom and rear for removal and for drainage.

The bionx bracket itself is hanging from some stout aluminum bits and two Bacchetta seat brackets.



Charlie
http://ElectricCyclist.com

 

[NeezyDeezy]

Thanks! I'll check it out.

Hi Nate,

I didn't notice your post.

It's called cohesive flexible bandage. It can be bought from any veterinary supply outfit. It comes in a lot of colors and widths and costs about $1 for the 4"roll. I also used it to wrap the top tube on my bike to hide the wires. The stuff works great.

http://www.jefferspet.com/ssc/product.asp?CID=0&pf_id=0029430

 

[bzhwindtalker]

I used 5mm abs sheets. waterproof, rigid, and plenty of room inside.
hides the motor, the belt and the wires.



get fun

 

[chrisvw]

LOTS of great ideas here. I do have one question for those of you that have put the battery/controller in the center triangle:
Does the width interfere with pedaling? I'm pretty religious about using my bike as a "hybrid" human/electric and I can't round-trip to work and back unless I pedal or leave a charger at work. Any thoughts on what width starts to interfere with pedaling? I'm also well over 6 feet tall (2 meters), so can't just push the whole works to the front of the triangle as my knees would be in the way.

 

[dogman dan]

My triangle mount of ebikes -ca nicads was about 4" wide. I could scrape a leg on it, but rarely did. So 4" is definitely ok for me. Pedaling bowlegged would allow more though.

 

[amberwolf]

Just need to install the extra wide bottom bracket and pelvis.

 

[GCinDC]

if you want lifepo4, ping can custom build L shaped packs that fit in triangles. my first pack from him was 12.5" x 5.5" high by 3" wide (not an L tho), which was nowhere close to touching my legs. I'd go up to 4" but no wider than that. my current pack is two lipo packs wide and just about 3" wide.

 

[dogman dan]

Definitley ping cells are narrow enough, with some kind of box, they could easily be less than 4" wide. Big triangle hardtail frames easily fit a stock 48v 15 ah or 36v 20 ah.

 

[ebent]

Made from star board. Used in boats. Unaffected by weather. Will not sand, paint, or glue. Tools great. Planes. routes, saws, files etc..Holds screws, proper pilot hole required.
ebent