Recommend Tail Bag &wiring solution

[rogerc]

Making progress on my Cellman kit and will post a build thread once I have completed the build. This build is for a MTB on fire roads, good condition trails etc. (nothing too rough).
Looking to mount my 9 fet IRFB3077 Infineon Controller in a tail bag. I am using a Topeka rear rack that has sliders to mount the bag but all those bags are way too big.
Bag needs to be able to keep the controller cool and protected. I will never be riding in rain so being waterproof in not necessary.
I have searched the internet but just can't seem to locate the ideal bag.
Also how does everyone keep the wires coming from the controller attached, stable and safe?
Was going to put electrical tape over the connectors and heat shrink wrap where I can.
Is there a better way?
Also would like to rewire the 6 phase wire connector to something easier to connect and disconnect and that would protect these fragile looking wires.
What are the alternative connectors to splice or solder in?

Can't say enough about this forum, I am not a great mechanic and had zero knowledge of electronics when I started this and I can actually picture where this build is going to work and be an awesome ride.
Thanks for a great community.
Another big thanks to Grin Technologies for their website, calculator, knowledge and ETHICS that keep all of this going.
RC

 

[amberwolf]

If keeping the controller cool is a requirement, then putting it into a bag *at all* is not the best choice, because that will prevent airflow over it, and keep the heat it produces inside the bag with the controller.


If you used an open-mesh bag, like some "gym bags" (meant to let your gym clothes air out and not get all musty and smelly when you forget to take them out and wash them), it would be *slightly* better than a non-mesh bag, but it will still not pass nearly the same amount of cooling air over the controller that having it in the open would.


If you were to put an aluminum (or copper, etc) plate or heatsink on the *outside* of the bag, bolted thru a hole the bag itself to the controller, so that the plate or heatsink is in contact with the largest surface area of the controller possible, it would at least help a little with getting rid of some of the heat, but it also will not be nearly as good as haivng the controller outside the bag, in the airflow itself.


If heat isn't an issue, none of that matters-but if it is, you migh twant to reconsider putting the controller inside the bag during operation.


Regarding connectors, evne on crazyBike2 I don't have any issue with them just comin gloose, using the orignal andersons and JSTs that came on the ebikes.ca / Grin tech motors and controllers and CA, though I do have the cables lightly ziptied to the frame beofre and after each connector, for the most part (within 6" to a foot of the connection, not right at it, in case I need to unplug something quickly if that ever happens).


As for quick plugs...I just use blocks of andersons already snapped together in a non-reversible-by-accident configuration. I am stil lusing the original JSTs for now, just with petroleum jelly inside them and hte andersons to keep water out. Dielectric grease like form car batery connectors works better, probably, but this sems ok so far.


Some poele use old bike tubes tied down over the connectors to keep water out.

 

[jimw1960]

I bought a set of Nashbar panniers carry my 48v 10Ah battery that weighs about 13 lbs.
http://www.nashbar.com/bikes/Product_10053_10052_165648_-1___202599

They are pretty durable so far. I just mounted the controller on the rack itself.

 

[dogman dan]

Mount that controller right on the rack top, or to the front of the bag if you have a bag or box. It won't be cool inside a bag. Easy to cover the plugs good enough for riding in light rain, or splash through mud.

 

[Eprilia]

I've been using the Topeak seatpost rack and tail bag for about 4 months and have had great success with it.

http://www.topeak.com/products/bags/MTXTrunkBagEX
http://www.topeak.com/products/Racks/MTXBeamRackE-Type

My commute is 17mi each way and includes a stretch of fireroad. I also have done some trail riding at Don Edwards park next to the Dumbarton bridge. My controller is in the mesh bag on top of the bag with the cinch cord pulled tight around the end of it. The cables are routed into the bag through a hole under the controller. All of the wiring is located in the front of the bag and separated from the battery with a divider that comes with the bag. It all works very well.

Pics are here https://skydrive.live.com/redir.asp...Bpub=SDX.SkyDrive&Bsrc=Share&sc=Photos&type=5

 

[heavymetalthunder]

I've wrapping my connectors in a Zip Loc bags and then seal the ends with some sealer and a zip tie. So far this has done a good job keep out moisture and dirt but will still allow me to get into the connector when I have to do maintenance. The problem is after a year or so the bags needs to be replaced. I keep my speed controller mounted on the side of my bike in the breeze.

 

[dogman dan]

I was thinking a bag that does not let air in. A mesh bag would be fine, if your bag has that.

 

[rogerc]

I've been using the Topeak seatpost rack and tail bag for about 4 months and have had great success with it.

http://www.topeak.com/products/bags/MTXTrunkBagEX
http://www.topeak.com/products/Racks/MTXBeamRackE-Type

First nice ride!
Second that bag looks perfect. Adds some cushioning, is out in the air, and a place for the wires!!
Will probably go that way soon.
Thanks everyone for the replies, as usual a good solution was obtained from this forum.
Actually I had given up on that bag thinking it was just too big. But seeing the Eprilia but it into use it is great and just what I was looking for.
RC

 

[Eprilia]

Actually the bag on my bike is the MTX TrunkBag DXP
http://www.topeak.com/products/bags/MTXTrunkBagDXP
Its large (23 L), but the panniers unzip from the side and are great to have with you always. They are extremely handy. I pack 5 days of work clothes in them on Mondays and Fridays.

The bag link in previous post is only 6 L in capacity, but still has the mesh top bungee that is perfect for a controller. I started with this bag and moved up to the larger one. My dropped top tube prevents me from carrying my battery in the triangle so it goes into the bag along with the charger every day. I'm running an Allcell 48v 13ah and it weighs less than 9 lbs. so handling isn't so bad (except on Mondays and Fridays) when I'm carrying over 22 lbs back there. Good luck with your build.
Chuck