Show Us Your Homemade Battery Housing

[flyinmonkie]

Thanks spinningmagnets... here is the finished box, minus paint.

Clay

 

[spinningmagnets]

Although I prefer the rectangle cross-section PVC tube for better support of the LiPo bricks, I like the location of these round PVC's. (flyinmonkie from NZ again)

http://endless-sphere.com/forums/viewtopic.php?f=28&t=19841&start=105#p338311

 

[flyinmonkie]

Thanks spinningmagnets. The batteries were wrapped in ultralon foam padding and couldn't move in the tubes. The round tubes gave me just enough room to fit the wiring beside the batteries easily. The batteries wouldn't fall out even if held upside down with the lid off. I went to the big box as the tubes limited me to only four lipo bricks and I wanted more range. It also shortened all the wiring and put all the electronics in the box instead of spread around the bike.

I do miss being able to pick the bike up from the top tube and I did like the of it in that configuration though.

Clay

 

[spinningmagnets]

From Obiwan007, heat-bent ABS for the housing, looks easy, professional results.

http://endless-sphere.com/forums/viewtopic.php?f=2&t=46942#p695878

 

[spinningmagnets]

From atom1025, fiberglass over a temporary foam core.

http://endless-sphere.com/forums/viewtopic.php?f=3&t=47631#p698781

 

[999zip999]

I have seen and read some about ABS and how it's heat bend but how strong is it or is it just a cover ?

 

[CogHog]

View attachment 1Someone suggested wood so I went with that. Light easy to work with. Catches fire. I can put two 14s packs in there.

 

[spinningmagnets]

Owner is claiming 36V 10S LiPo, but only 5-Ah

http://endless-sphere.com/forums/viewtopic.php?f=2&t=16535&start=45#p249423

As long as I found a bottle-battery, here's another. 36V 5-Ah inside a 1.5-liter bottle using Konion cells.

http://endless-sphere.com/forums/viewtopic.php?f=6&t=19872&start=30#p381966

 

[smudger1956]

View attachment 1View attachment 2Someone suggested wood so I went with that. Light easy to work with. Catches fire. I can put two 14s packs in there.

Stunning bike CogHog, is there a build log..?

 

[CogHog]

Not much of a log or extended procedures. Just watched some take this Specialize frame out of their trunk and put it next to the dumpster. Liked Indians so designed the tank to use t-nuts to hold it up to the frame with copper straps. Velcro to hold the cover on but did not need it. Just hook the lexan on with #6 screw heads. Easy to take the sides off (see jpg TANKS). Hide the wires in the oil can. Rhino Lite rims, Old Schwinn handlebars up side down. Hand stitched vinyl covers on the grips. No CA but thinking of a tiny led voltage display in some stealthy place to monitor the discharge. For Sale at some point without Batts. Seat was moved forward from this pic. Tank cone made of balsa wood.

 

[miro13car]

my battery box is made of ABS sheets, aluminum sheets,
mounted low in the frame
with low L C of Gravity for beautiful handling

 

[whereswally606]

Here is my DIY lipo holder.

16 blocks of 3s 40c 4ah zippy flight max loco
Paralleled inside by my custom phase bus bars and balance tap strip board bus bars in 3s4p blocks. Able to separate the pack into two halves of 6s4p and parallel to charge on one bc168.

Casing is manrose PVC ducting. clamps are hydraulic pipe clamps with the hole made larger using a simple hole saw. pack is about as low c o g as I could get and make the bike handle way better than my other one with a seat post mounted vertical pack.

 

[spinningmagnets]

Wooden/bondo mold, carbon fiber outer skin, fiberglass walls...BEAUTIFUL !!

http://www.cycleexif.com/paul-brodie-ebee-part-4

 

[Arlo1]

A lot of work went into those, very nice. I have built and am still finishing some carbon fiber and its a crazy amount of work.
Great job!

 

[spinningmagnets]

from kfong. Foam core to make a mold, panels laid in mold are carbon-fiber skin and fiberglass body.

http://www.endless-sphere.com/forums/viewtopic.php?f=6&t=12654&start=25#p233633
http://www.endless-sphere.com/forums/viewtopic.php?f=6&t=12654&start=150#p527393

 

[boo]

Battery and Controller enclosure made out of scrap(oxidised copper) double sided PCB.

 

[spinningmagnets]

From mushymelon, carbon-fiber cloth over fiberglass, temporary foam core for shaping. The shock on the rear suspension must be taken off to remove the battery housing from the frame, very smart...less steal-able, but...still accessable.

http://www.endless-sphere.com/forums/viewtopic.php?f=6&t=45719#p701444

 

[Spooky1]

What a great thread! I've only just found it!

 

[3nslav3]

4 of these + other stuff:

equals:

 

[Spooky1]

Got many ideas for this battery box from this very thread!

 

[spinningmagnets]

Spooky1, this is an incredibly professional-looking battery box and controller set! Do you have the links for the individual parts for those who might wish to copy some part of it?

 

[Kingfish]

I am always impressed by the DIY hardshells; really nice work there! I wish I had a garage for projects like that. Through the years I have made several assemblies leveraging hand tools and an industrial walking-foot sewing machine.

This is the Chilly Hilly version with the Triangle Bag & Rear Boot bag. Easy to find these items at most bike-handy stores. The Triangle bag came with my kit from Ebikes.CA, and the boot bag came from REI. I used high-density closed-cell foam for protection. I could fit 6 to 8 batteries in the Triangle, and up to 14 in the boot bag.

For my first cross-country road trip in 2010, I moved all the batteries to the panniers. A simple aluminum shield was constructed to retain the shape and prevent crushing. See below...

Though it could hold up to 12 per side, I used 9 for each pannier so as to have room for food.

Then I created a large capacity battery bag assembly using two camelback bags sewn together. It went through a few permutations until I found a configuration that prevented it from getting wet. Each side holds 9 batteries.

Original w/ boot bag strapped on board.

Started adding fairing bits of shielding...

Full-wrap of HDPE, though still getting wet.

The pre-2WD version has a double-wrap around the bag: Tough marine vinyl inner wrap is water-repellant, with a high-contrast wind-slippery HDPE outer wrap which makes it easy to wipe down and keep clean.


Then I built a trailer that used two Sears Craftsman toolboxes to carry the largest assembly for my 2011 road trip.

Inside view: The front is to the left. Though it could hold more, I settled on 15 per side.

In addition, I have a saddle bag made from two Timbuk2 Front bike bags that lays over the top of the triangle assembly; it's on the right and each side holds 6 batteries. The left packaging is for the trailer and allowed me to quickly remove it for balancing when required. The center packaging is for the panniers.

Altogether – it looked like this for the 2011 road trip:

I continue to scheme up ideas with necessity being the mother of invention. Lots of ways to skin the kitty. Though I still pine for a really nice hard-covered solution as the ultimate protection against the unwanted collision :wink:

Safe travels, KF

 

[ambroseliao]

I would love to see how the wires enter/exit this gorgeous case!

Spooky1, this is an incredibly professional-looking battery box and controller set! Do you have the links for the individual parts for those who might wish to copy some part of it?

 

[Spooky1]

Wow, thanks! Sure I'd love to help if people want to know.

The main body is simply an 'ABS Project Box' from fleabay, they come in all sorts of sizes and 3 colours-Black/White/Grey. They are very study and flame resistant apparently.

The aluminium surround is just 1.5mm thick and bent to accommodate the Alien ESC, I wanted them separate to keep them both cool.

The ESC is one of Bruno's Alien Powered ESC, he is on here as Bruno Tollot, tbh the ESC makes the box look amazing.

 

[Spooky1]

I would love to see how the wires enter/exit this gorgeous case!

Thanks Ambroseliao! I am waiting on a few more parts which should be here soon, then ill do a open lid shot!