Show Us Your Homemade Battery Housing

SHARKBITEATTACK said:
Mundo, that aluminum work is so clean looking. Nice work!
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Thanks, I need to weld corners but have no MIG. I tried low temperature aluminium welding but it simply doesn't work (with me). I'll try epoxy/metal mix paste ...
 
spinningmagnets said:
cybug, c'est magnifique! At last we are seeing 3D-printed parts for E-bikes!
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Merci ;) Each part is a couple of hours to print but once the 3D printer is fine tuned you can do it while sleeping (or working on something else on the e-bike). ABS is great for this kind of parts, you can drill, cut, sand, weld, paste it ...
 
Some great looking enclosures on here - real works of art 8) . This is my first e-Bike build and only very basic tools so kept it simple going for function over form ! Used Glosstex covering, softwood where necessary for strength/fixings, balsa where not, marine plywood sides / base and wood inserts for screws fixing recessed servicing panel. All internals/externals had 2 coats of Clearcoat before covering. Total weight 900g including fixings.





Was going to put some decals on it / pretty up a bit, but the bike gets a bit of a hammering off the roads and still haven't got around to it ! Fixed using 2 downtube bottle holder screw holes (under the foam) and one of the seat tube ones with large washers epoxied on, along with a single external bracket over the top tube. Frame is cut out to allow independent removal of controller and battery if needed. Rock solid.





Routes all wiring, 4 inline fuses and (just) houses 36v 20Ah Li-Ion battery, KU123 controller, side-mounted 12V marine charging socket, 8-way BUSbar, 3 DC-DC converters for lights + hardwire phone/GPS charger & 12v charger, soft start switch / Cycle Analyst shunt. Battery charging is via panel mounted XLR socket (very user-friendly) and there are 2 switches, one for the controller and another to isolate the supply to tapped accessories & horn.



 
From jimnasium, a laser-cut battery box of his design:

http://endless-sphere.com/forums/viewtopic.php?f=6&t=54939
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I have still yet to create a post that shows before and after on my bike, but this looks like the next best thing, especially since the battery housings were the main components I fabricated on my build. I am not going to rattle on, here are the pics. Enjoy! Sorry if some of the captions are difficult to read.
 

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Hey there ES members. I am currently attempting to build my own battery box. I am wondering if there is already a thread started about custom and or mass produced battery cases. If not I will start one in the photo/ video section.
 
Not as professional as you guys but I think it will do until I decide what to do ? Just used some folded coreflute.
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I will try to add some more info on my build log here...
http://endless-sphere.com/forums/viewtopic.php?f=6&t=55352
 
My first real eBike. This is wood enclosure I built to hold 8 Turnigy 6S Lipos. I attached the enclosure to both bottle mounts to make it secure. Then hid it in Falcon EV Frame Bag.
 

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drew12345 said:
My first real eBike. This is wood enclosure I built to hold 8 Turnigy 6S Lipos. I attached the enclosure to both bottle mounts to make it secure. Then hid it in Falcon EV Frame Bag.
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I really need to sort something out for my batteries and quite like this idea. I currently use one at a time held in a topbox on the rear carrier- not ideal.

I've never really worked much with wood but no longer have a garage/shed so am limited when it comes to working with metal- I would really have preferred aluminium.
Anyhow I have 2 x 36V 15Ah batteries, the intention is to mount them a bit like rear panniers. I thought a bit about using wood before but really have little experience.

Some advice would be appreciated on materials etc. What kind of wood should I be looking for? Rain isn't unusual here so is chipboard to be avoided, or is it ok if painted? What sort of wood should I be using? What thickness? What about treating the wood- is normal gloss paint ok, or some kind of wood treatment? Side panels thinner, or possibly just aluminium sheet.

Thanks for any advice.
 
Hi. I haven't worked with wood much. I just went to Home Depot, bought what looked decent. I ended up getting 3/8 inch hobby board. It's durable and strong and doesn't splinter. I then got some corner braces from door section, bent them to angle I wanted and connected the pieces together with screws. Again, not big on carpentry skills but somehow it worked out. We'll see how long it will last :)
 
drew12345 said:
Hi. I haven't worked with wood much. I just went to Home Depot, bought what looked decent. I ended up getting 3/8 inch hobby board. It's durable and strong and doesn't splinter. I then got some corner braces from door section, bent them to angle I wanted and connected the pieces together with screws. Again, not big on carpentry skills but somehow it worked out. We'll see how long it will last :)
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Have you painted it? Have you a bit of the wood left to see what happens if it gets wet? I know some of the boards are made up of wood 'powder'? and bonded with an adhesive under pressure but wondered if they will withstand getting wet.
 
nice find! And no text to try and understand, some of them are quite interesting. I gather there are no regulations for ebikes in Russia so there's probably a few powerful ones kicking around.
 
are you using some kind of adhesive where the sheets join, or just the L-brackets? what thickness and type of plastic have you used? Thanks
 
hello

Box 10cm wide :)
15Ah at 18S lipo zippy in this box + fuses and some cables.
Box is made from aluminium with some steel elements to make it stiff.
Its mounted into the frame by 2 bolts of water bottle in the middle + passed steel elements on top with epoxy at every matching element to the fram shape. :)
Its not shown on picutre but i still have 160mm (fork) of space from the wheel to box.


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soaresdacosta said:
Hi,

alsmith, yes I use an epoxy glue, I try lots of them, until I find one with good results. The L-brackets give a lot of resistance to the box. Its acrylic, 5mm of thickness. To make the cuts, I use an X-knife...I try everything, saw, grinder, Dremel...

Luis.
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Thanks. Which brand of epoxy have you used?

I've been wanting to make something for my batteries for a couple of years now but looking for a simple method. Mine will need to be mounted as panniers either side of the back wheel though, it's the strength of that bottom panel that's been a bit of a concern because it's not resting on anything for support. The batteries weigh about 6kg (13lb) so need to have confidence in that base panel.
 
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