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  • misko903
    started a topic custom triangle battery box

    custom triangle battery box

    hello guys,
    i am building my first ebike. my original bike is about 11 years old, now comes the time to convert it.
    i will use bafang bbshd drive. i want to use lipo batteries. the problem of used bateries is their format. i will use 4x6s 12ah or 4x6s 16ah.
    the width of the box - on the picture needs to be 80mm +2x2mm wall thickness. my bottom bracket is 68mm.

    question - will i have problems banging my knees to the box, or is it okay to have box cca 84mm wide

    question 2 - is it worth to have 2kg more and have 8ah more

    thanks for answers,

    miso, slovakia
    width how will it looks like

  • JPLabs
    replied
    Weatherstripping from the hardware store is one easy way, for a removable panel.

    I find weatherstripping is too thick and not sticky enough. I like to use thin foam rubber mat, such as cheap toolbox drawer liner. Cut one big gasket. Attach with contact cement. Both sides, let it dry. Press in place.

    Then wax the unglued side, or wipe with silicone, so it comes off easily after being clamped to the box a while.
    Last edited by JPLabs; 01-31-2018, 04:10 PM.

    Leave a comment:


  • misko903
    replied
    So I put the Alu box (only half of it) into a carbon foil. Pro - looks much better, Con - attract more sun - batteries will become more hot during summer days. I bought few of these screws dedicated to furnitures. Planning to connect the boxes with the screws.
    Any idea how to seal the box? I need to open it from time to time to balance the batteries and to check if the moisture does not get in.

    M

    Leave a comment:


  • JPLabs
    replied
    Right, it's American Yacht Association approved, or what. But no IP rating. I'd say, not waterproof, but ought to be OK for damp environment s.

    Leave a comment:


  • misko903
    commented on 's reply
    Thanks for the picture. Seems to be not waterproof too. I am wondering if we are pioneers of electrobiking, that the proper solution does not exists.

  • JPLabs
    replied
    Mines a Luna triangle pack and BMS.

    NO! No chassis ground. Certainly not.

    This is the breaker/switch. It is designed to be used as a switch, too, as opposed to many breakers. Note AC rating 250V, DC only ranges from 36V to 65V depending on the model, I think. Versions to 50A. Again, have not used it so not personally tested, but looked good on paper and looks quality in person:

    https://www.bluesea.com/products/cat...r_Style=Toggle



    Click image for larger version  Name:	51w5KoDHtwL.jpg Views:	1 Size:	38.4 KB ID:	56194
    Last edited by JPLabs; 01-21-2018, 08:40 AM.

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  • misko903
    commented on 's reply
    Mine is 125V DC circ. breaker. Do you have a picture of your marine c. breaker?*
    I don't use BMS, I will balance the batteries manually with balancer.
    Which BMS are you using, or which you recommend for my setup?*
    Are you using a ground to the chassis?*
    ​​​​​​​M.

  • JPLabs
    replied
    Originally posted by misko903 View Post
    Chainwheel changed from original Bafang 46T to Luna 42T. Well... to say tomething about Luna Eclipse:

    Pros:
    - looks sexy
    - weight half
    - big teeths does not allow chain to drop

    Cons:
    - Lekkie is lighter
    - I need to use the spacer, because the chainring was touching the frame -> offset 24.8-3.3=21.5 vs Bafang stock 19 and Lekkie 20.4
    - Paid roughly 130€ including import taxes, Lekkie is cheaper
    - For the price of 130€ I still need to visit several hardware stores to find specific allen key stainles steel screws (used the spacer). Does it cost Luna so much to add 5 screws more to the set with spacer?

    I have not tested it until now, as the weather outshide is ugly

    The circuit breaker will stay in the box.

    What about the SWITCH?

    Is anyone using any suitable switch on the box?

    Michal
    I would choose the 125V breaker over the 12V one. Higher voltages need more careful design to prevent arcing when contacts open under current. Further, is that 125V AC, or DC? Needs to be rated for your DC voltage, you can't substitute AC gear. AC can self-extinguish arcs better, since it's turning on and off.

    I bought a marine DC rated breaker to use as both protection and switch, but decided I didn't need the switch feature, so didn't install the breaker, either. I also rely on BMS for short protection in the large power wires.

    I DO use fuses for my pack level accessory circuits, though. To protect the wiring and thus to keep my bike/shop from burning down in case of short. A short in thin wires may not pull enough current (60A, etc) to trip the BMS before the wires get white-hot and then melt, probably with arcing. That's obviously worth taking precautions.

    Hope that helps with your decisions.
    Last edited by JPLabs; 01-19-2018, 03:20 PM.

    Leave a comment:


  • misko903
    replied
    Chainwheel changed from original Bafang 46T to Luna 42T. Well... to say tomething about Luna Eclipse:

    Pros:
    - looks sexy
    - weight half
    - big teeths does not allow chain to drop

    Cons:
    - Lekkie is lighter
    - I need to use the spacer, because the chainring was touching the frame -> offset 24.8-3.3=21.5 vs Bafang stock 19 and Lekkie 20.4
    - Paid roughly 130€ including import taxes, Lekkie is cheaper
    - For the price of 130€ I still need to visit several hardware stores to find specific allen key stainles steel screws (used the spacer). Does it cost Luna so much to add 5 screws more to the set with spacer?

    I have not tested it until now, as the weather outshide is ugly

    The circuit breaker will stay in the box.

    What about the SWITCH?

    Is anyone using any suitable switch on the box?

    Michal
    Chainwheel changed

    Leave a comment:


  • misko903
    commented on 's reply
    It is not so hard, but you need to have a bend tool for roughly 600€ and a workshop :/
    My setup would be too heavy. 8kg batteries. Maybe half of it and shark case as you said... It will look much nicer.

  • misko903
    replied
    Originally posted by Robert62 View Post
    Looking good. Is that box welded?
    Robert
    Yes, welded by local welder. Cost me 70€. I will glue it into the frame.

    Leave a comment:


  • Robert Larrison
    replied
    My next project is an aluminum shark case and a locking aluminum triangle case
    I was looking at some drawer sliders at Lowe's that would be perfect
    I don't plan on including the battery connection into the slider system

    I've built custom aluminum boxes with hand tools its not that hard
    https://makezine.com/2011/12/07/bend...omemade-brake/
    http://www.instructables.com/id/A-ri...-box-with-lid/
    Last edited by Robert Larrison; 01-11-2018, 01:36 AM.

    Leave a comment:


  • Ebike1
    replied
    I don’t use a fuse.
    My XT90 connectors vaporized whenever I had a short.
    Usually from soldering the B- and B+ backwards on one side (on those long nights of building without sleep for 24 hours)

    Leave a comment:


  • Robert62
    replied
    Looking good. Is that box welded?
    Robert

    Leave a comment:


  • misko903
    replied
    My temp solution is to close the circuit breaker to the box. No weather problems... and instead of switch i will disengage the plug everytime. lets see how it will work.

    Leave a comment:

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