Magnispanna
1 µW
Hi All,
Thought I would share a strong and cheap method of securing a battery pack. After a few thousand km of commuting on my DD hardtail, its proving very solid and easy to use, would easily handle off-road conditions.
The basis of this design is 2x stainless over-centre latches from any hardware store, attached to 2x shaped brackets cut from kitchen chopping board (9-10mm thick), and secured to the frame with a few of metres of thin bungee/shock cord, laced under tension, for a huge, compliant clamping force:
View attachment 4
To prevent the battery from rotating around the frame, make a small platform from aluminium angle iron and attach to a bottle mount with a countersunk screw:
The battery pack (1P16S, 10.4Ah, LiFePO4, Headway 38120S), also has chopping board top and bottom plates. I didn't have enough room to use the orange headway battery holders, so I stacked the cells closely together and protected each cell from chafing with rings of inner tube slipped over each cell. Enclose the sides with plastic sheet (2mm thick plastic cut from an old Intermediate Bulk Container liner works very well). Ensure all cables run neatly and are not crushed (I used spiral wrap). Screw together with 8Gx18mm self tapping stainless screws for a very rugged pack.
It's then easy to screw the BMS, breaker switch, connector etc. to the board, taking care not to screw too far through the plastic to the cells inside.
View attachment 1
This set-up is compact enough to fit inside small frames, and is very quick to unplug and unlatch... All the features of a Dolphin pack for essentially the cost of the cells and BMS. Plus up to 100A available from the Headways...
All the best
Thought I would share a strong and cheap method of securing a battery pack. After a few thousand km of commuting on my DD hardtail, its proving very solid and easy to use, would easily handle off-road conditions.
The basis of this design is 2x stainless over-centre latches from any hardware store, attached to 2x shaped brackets cut from kitchen chopping board (9-10mm thick), and secured to the frame with a few of metres of thin bungee/shock cord, laced under tension, for a huge, compliant clamping force:
View attachment 4
To prevent the battery from rotating around the frame, make a small platform from aluminium angle iron and attach to a bottle mount with a countersunk screw:
The battery pack (1P16S, 10.4Ah, LiFePO4, Headway 38120S), also has chopping board top and bottom plates. I didn't have enough room to use the orange headway battery holders, so I stacked the cells closely together and protected each cell from chafing with rings of inner tube slipped over each cell. Enclose the sides with plastic sheet (2mm thick plastic cut from an old Intermediate Bulk Container liner works very well). Ensure all cables run neatly and are not crushed (I used spiral wrap). Screw together with 8Gx18mm self tapping stainless screws for a very rugged pack.
It's then easy to screw the BMS, breaker switch, connector etc. to the board, taking care not to screw too far through the plastic to the cells inside.
View attachment 1
This set-up is compact enough to fit inside small frames, and is very quick to unplug and unlatch... All the features of a Dolphin pack for essentially the cost of the cells and BMS. Plus up to 100A available from the Headways...
All the best
