Custom battery cases - how to make?

[UtahPete]

On Facebook, there is at least one group doing ebike battery builds, including some that have made their own battery case from fiberglass. Is anyone here doing that, with how-to's? I couldn't find a forum or thread with that info. Thanks.

 

[nicobie]

I just did a quick google search: 'How to build an ebike battery from fiberglass.'

Custom fiberglass / carbon frame battery case

Hello there, I'm planning to build my own case to use as much space as possible. I ordered 21700 cellholders and was able to fit 112 cells (14S8P). I'm riding a Bafang G510 + X1 3500W paired with DP-9 18650 14S6P VTC6 in my converted Haibike: I want to build an fixed case, that is similar to...

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There was more than one result.

 

[E-HP]

Fiberglass or Carbon Fiber are options, but I have so many volatile chemicals already in my garage, that I don't want to add to the combustible mix.

I'm seeing so many ebike applications for 3D printers that this old dog may need to learn some new tricks. I haven't researched any of it yet. I remember several years ago when I was still working, I had a staff meeting and people were talking about hobbies. One young engineer said he had a 3D printer, and everyone ooo'd and ahh'd because they hadn't gained popularity yet. I remember thinking, what the heck would I use that for? Now I'm realizing the answer is just about everything.

I've seen a few examples on this forum on printing parts, but there lots of examples on the net with both free and paid files of different battery case configurations as well as for the cell holders that go inside. I'm moving slow at researching this stuff, since once I do, then the money is as good as spent, but I'm serious enough to be looking at where I'm going to put it. I'll need to brush up on CAD and get some software, but I think I can figure it out (Back when I was a newer employee, they asked for volunteers to pilot a new CAD system, when CAD first came out. Each UNIX workstation was as big as a dining room table, and we had a big air conditioned room dedicated to the mainframe and huge, in physical size, disk packs. A whole room with a fraction of the storage and processing power of an iPhone LOL).

Your Creation's Before & After Pics

Nice wheel! Where’s the rest of it! My latest build is a lightweight short range eMTB. I live very close to a hill with approx 300m vertical climb, and some great rocky trails for going downhill. You have to lift the bike over fences in places, so I wanted something light, mid drive for...

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Hawk Classic - “stealth-ish” build

So this will be my build thread for my stealth-ish build. The bike is a Hawk Classic Sunbeam. It is a german bike built in aluminum, the company went bankrupt, but the bikes lives on :) This is what it looked like when I bought it Since I will be using this most of the year and I live in a...

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why not vertical stacking of 18650 battery pack

Hi everyone, I searched the forum but I could not find a reference. and I am a newbie so My question might be naive. Having said that I plan to build a battery pack for my ebike. But I would like to know why no one is packing batteries vertically one on top of each other like a flashlight set...

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[amberwolf]

On Facebook, there is at least one group doing ebike battery builds, including some that have made their own battery case from fiberglass. Is anyone here doing that, with how-to's? I couldn't find a forum or thread with that info. Thanks.

Dunno how much detail they go into, but there have been a few here on ES, at least two threads come up in one possible search

ES 1.0 Graveyard - Search

and there is a thread somewhere here for showing of DIY battery cases.

 

[UtahPete]

Dunno how much detail they go into, but there have been a few here on ES, at least two threads come up in one possible search

ES 1.0 Graveyard - Search

and there is a thread somewhere here for showing of DIY battery cases.

Those links were helpful. Thank you.

 

[Hummina Shadeeba]

I think easiest and cheapest is get polycarbonate or even acrylic sheets cut at Tap plastics or somewhere instead of 3d printing (this was 40$). Glue them together or they will do it for u. Layer fiberglass, carbon, or aramid, and maybe add some peel-ply at the end, then dremel the excess off. I think with polycarbonate it will very likely be stronger than printing. Gluing polycarbonate is essentially welding


This pic shows before doing a final resin coat and I’ll add a strip on the top rim first. It’s easy to make it look good and this will look pretty flawless after the final coating (The peel-ply didn’t adhere everywhere so looks a bit messy still)

 

[UtahPete]

I think easiest and cheapest is get polycarbonate or even acrylic sheets cut at Tap plastics or somewhere instead of 3d printing (this was 40$). Glue them together or they will do it for u. Layer fiberglass, carbon, or aramid, and maybe add some peel-ply at the end, then dremel the excess off. I think with polycarbonate it will very likely be stronger than printing. Gluing polycarbonate is essentially welding


This pic shows before doing a final resin coat and I’ll add a strip on the top rim first. It’s easy to make it look good and this will look pretty flawless after the final coating (The peel-ply didn’t adhere everywhere so looks a bit messy still)

Do you have any pics of the final product, including waterproof lid, bike attachment, cells and bms inside?

 

[fechter]

I have made a few custom batteries but I used something off the shelf for the case.
Here’s one I made with a plastic ammo can
Thread '.50 Cal Ammo Can 18650 build'
.50 Cal Ammo Can 18650 build

I made another one from a small Pelican case.
Sur-ron mods

 

[E-HP]

I have made a few custom batteries but I used something off the shelf for the case.
Here’s one I made with a plastic ammo can
Thread '.50 Cal Ammo Can 18650 build'
.50 Cal Ammo Can 18650 build

I made another one from a small Pelican case.
Sur-ron mods

Well the battery on your fat bike is possibly the best looking pack I've ever seen, and the metal sides add a cool industrial accent.

 

[Hummina Shadeeba]

Do you have any pics of the final product, including waterproof lid, bike attachment, cells and bms inside?

Not done yet and still deciding what to do to waterproof it. Just going to winch strap it to the frame
Do li-ion cells turn to flame throwing if shorted w water?

 

[UtahPete]

I have made a few custom batteries but I used something off the shelf for the case.
Here’s one I made with a plastic ammo can
Thread '.50 Cal Ammo Can 18650 build'
.50 Cal Ammo Can 18650 build

I made another one from a small Pelican case.
Sur-ron mods

Nice.

 

[amberwolf]

I found that old thread about cusotm housings:
"Show us your home-made battery housing"

Show Us Your Homemade Battery Housing - ES 1.0 Graveyard

current version

Show Us Your Homemade Battery Housing

I thought I might start a thread so we can show off our innovative methods for housing a battery on an ebike. I'll start with the one I just finished. The blue box on this bike is the battery housing I just finished building out of 63 mil aluminum sheet stock. It mounts to the water bottle...

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and also
"Your creations before and after pics"

Your Creation's Before & After Pics - ES 1.0 Graveyard

Your Creation's Before & After Pics

Post your wonder-bike's before and after pics. See if we can guess which is the before, and which is the after. :-) I'll go first. Who's ever the first to post indiscernible before and after photos wins the 1st annual "most stealth" contest... just have to figure out how'd we know if the...

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