Show Us Your Homemade Battery Housing

1.5mm thick tray fixed to the frame

721985PC311743.jpg


0.8mm thick cover + clamps to fix the battery to the tray

302097PC311745.jpg
 
Wow, you guys do some really good work!

When tasked with making a clean setup for my wife's bike, I went with leather panniers with wood sides. The wood sides allowed me to build a rigid frame with the batteries mounted to a shelf that can slide out for charging, and also was easy to make with no sewing! Just a wood frame wrapped in a single piece of leather.

15s2p worth of lipo on one side, and the controller, fuse, kill switch on the other. The controller is cooled by four 40mm CPU fans, two intake and two exhaust.

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maurtis said:
When tasked with making a clean setup for my wife's bike, I went with leather panniers with wood sides.
Click to expand...
Nice.

What torque arm is that? I've been looking for something like it, so any pointers you can provide will be appreciated. Thanks.
 
jimw1960 said:
pretty sweet looking setup there, maurtis. How well does it stop with no rear brake?
Click to expand...

Thanks! The front cantilevers and rear regen stop the bike ok, but you really have to want to stop. Rear calipers will definitely help. I ordered a set of Tektro C326 side pulls, but the reach was a little too short. So I have a set of the longer reach C324 calipers coming in.


The torque arms are the Grin Tech v4, I have one one each side. At these power levels one would probably be fine, but I always like a little extra piece of mind:
http://ebikes.ca/store/store_connectors.php
 
20140101_152405.jpg
battery comes off for easy folding and controller/wiring stays on frame
and some space in top of bag for some shopping also
 

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that look nice, I'd like to get one to be able to unplug my controller from my bike every time I need to park it.

How many amps can each wire carry? And where can I get them for cheap?

thanks
 
ivanovlev said:
"classical" variant, 1300 peli
Click to expand...

Huh. Looks a lot like my front mount design - I wonder if they were inspired by builds here, or developed the same solution in parallel. :D

-JD
 
cwah said:
that look nice, I'd like to get one to be able to unplug my controller from my bike every time I need to park it.

How many amps can each wire carry? And where can I get them for cheap?

thanks
Click to expand...

It is a through bulkhead connector. Many cars now use them. It enables doors to be taken off easily. About 10 wires is commonplace. The french use them through the front bulkhead though where more wires are present. It's easy on the assembly line to join wiring harnesses this way. I wouldn't bother though tbh, they don't carry much power. Although you could have a second plug for the higher power connections and just use one of these for the rest.

Great thread. I never thought about forming galvanised box section trunking or cable tray till I saw the wall stuff being used. How did I miss this thread..
I will post again when I can add some pics.
 
oatnet,

"inspired by builds here" and live visualization at AndreyM ;) My first solution (1200wh in 16s4p hardcase LiPo) for first bike looked like:

[youtube]p_vDXxxujJ4[/youtube]


 
friendly1uk said:
cwah said:
that look nice, I'd like to get one to be able to unplug my controller from my bike every time I need to park it.

How many amps can each wire carry? And where can I get them for cheap?

thanks
Click to expand...

It is a through bulkhead connector. Many cars now use them. It enables doors to be taken off easily. About 10 wires is commonplace. The french use them through the front bulkhead though where more wires are present. It's easy on the assembly line to join wiring harnesses this way. I wouldn't bother though tbh, they don't carry much power. Although you could have a second plug for the higher power connections and just use one of these for the rest.

Great thread. I never thought about forming galvanised box section trunking or cable tray till I saw the wall stuff being used. How did I miss this thread..
I will post again when I can add some pics.
Click to expand...

Thanks, do you know where I can find in europe connectors at decent price that could replace all the wires from my controller? I had used computer power plug they are absolutely not reliable and can't manage constant unplug-replug or vibration.
 
A connector for 5 cores rated for 15 amp is quite large. Something like a 7 pin uk trailer hitch or perhaps the 13 pin euro one, though I don't know the european one's spec.
On the other side of the coin, we have the 9? pin motor wires sold by the likes of bmsbattery. Tiny thing shown to support 15amps. http://www.bmsbattery.com/accessory/439-9pin-waterproof-cable-female-connector-for-motor.html
The pronged iec lead is vastly inferior to the round pin one. http://www.ebay.co.uk/itm/CABLE-JOINER-FOR-ELECTRIC-MOWERS-STRIMMERS-REPAIR-PLUG-SOCKET-3-CORE-WITH-EARTH-/400537906396
http://www.ebay.co.uk/itm/LAWNMOWER-PLUG-AND-SOCKET-CABLE-CONNECTOR-2-PIN-/360827176270

That last one might satisfy the needs of some battery packs. Just to keep it on topic a bit :)

edit: The car bulkhead plugs should be fairly common in breakers yards.
 
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