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    Show us your custom battery and or box here

    Please document you custom battery builds and cases here.

    This will help other forum members who may have a frame that may need a customized battery or case.

    #2
    Ok Guys I will start this off.

    Heres mine.

    A piece of aluminium which i used to hold my pack. I bolted it to the water bottle holes.



    The packs was wrapped in tap to ensure a tight fit.
    Click image for larger version

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    To finish it off I then covered the pack in carbon fibre wrap.



    Click image for larger version

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    Another option if I was unable to slide my battery into this piece of aluminium would have been to first bolt on a flat piece of plate to the bottle holder holes then slide the battery over this plate and then bolt both together.
    Last edited by Rodney64; 12-30-2016, 03:53 AM.

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      #3
      I needed a really tough battery box that fit tightly in my panniers (so as to maximize space). I bought a lot of aluminum bar and angle aluminum from Online Metals. I used a bandsaw to cut the aluminum, and I connected it all with rivets.

      The box is very strong. A car ran right into my panniers with one of these inside, and the battery box was not damaged. I have also gone down hard on the panniers on two occasions, and the boxes were never damaged. However, in all three of the above cases, the panniers were torn.

      Click image for larger version

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      • Max-Ebike
        Max-Ebike commented
        Editing a comment
        You need to mass produce these! Nice work!

      #4
      The battery boxes are bolted to a steel strap welded into the bike frame using 1/4" Grade 8 hardware. I drilled holes in the pannier to allow the bolts to pass through.

      Click image for larger version

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        #5
        That's pretty cool Commuter; it looks like you got center of gravity real low.
        Curious if you feel a sway or pull on corners from inertia of battery packs.
        I ask because when I mounted a shark on top of pannier rack I experienced that.

        Comment


          #6
          Originally posted by FatMarty View Post
          That's pretty cool Commuter; it looks like you got center of gravity real low.
          Curious if you feel a sway or pull on corners from inertia of battery packs.
          I ask because when I mounted a shark on top of pannier rack I experienced that.
          The weight is equal on either side, so there is no lateral sway. The few times that I have carried an extra battery (which fills the panniers at that point), I could definitely feel the extra 20 lbs. in the top of the panniers.

          I weigh 285 lbs. and the bike weighs 90 lbs., so adding an extra 20 lb. battery is only adding 5.33% more weight.

          I think it rides better with only one battery (i.e. a 10 lb. 36V battery at the bottom of each pannier).

          Another 10 lbs. in the top half of each pannier definitely makes it feel top heavy.
          Last edited by commuter ebikes; 12-31-2016, 12:29 AM.

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