Aviation connectors on my down pipe :)

Jestronix

10 kW
Joined
Jul 18, 2015
Messages
510
so me got to thinking about the best ways to go about a water resistant connection for my 26S battery pack. Then I came across some ip67 aviation connectors with 16 pins , any more than 16 pins and the actual pins became to small. Small pins are not what I want to charge at 5 amps. Aim is to always charge through the balance leads and have a balanced pack. BMS is a long story....

So my cells are loaded into some square downpipe which runs along my bottom bar, 26s keeps the pack to the 5kw power peak I'm after and gives me around the half kWh I'm after. A light pack to keep the bike nimble.


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As u can see pins are pretty thick and my wires are also 10amp rated, not sure on pin ratings for these so keeping at 5 amp max

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Nice dust caps and water resistant


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I decided to have the charge ports up nice and high away from water splash. Overall happy with the setup.

Learning to solder the pins was interesting with some fu#}^{ moments , but got there in the case end, I hot glued the pins after soldering to waterproof and held hold the wires I'd one came loose.
 
No, but I considered it; I have parts of some of the connectors for that (just not both male and female of the ones with enough pins).

I stopped worrying about it, though, because the main pack I use (EIG NMC) stays in balance, and the secondary pack (A123) has a BMS to do it for me (assuming it doesnt' stay in balance anyway). ;)
 
Ill pretty much use these on all my battery builds now. After using these for a few months, they are awesome, quick and easy connect-disconnect. Full independent cell charge each time. I push around 600w through these connectors :)
 
38999 MIL STD
I get them from Glenair. 6 week lead time.

Amphenol also has them.

Many pinout options 1.5A to 5A rated pins for aircraft easily double anywhere else.

Check Mouser.
 
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