finally got to building the box for the 52v 24ah Ga battery, in the triangle. The 2008 turner frame just fits this battery. You'll have to make sure you have enough room. I made a cardboard pattern of the battery and it fit in the triangle, there was some room for 1/4" of padding inside the box. I used 16ga. aluminum with 1/8".for the bottom piece to mount solidly to the rivnuts. The box needs to fit the frame triangle, leaving 1/4" around the battery, I cut the pieces myself, but gave up after trying to weld the thin pieces with a spoolgun. My local welder did it for 200$. Spendy, but it's awesome and mine now! I cut the pieces so that they met at inside measurements. Clamped to a short piece of angle iron at each end, the pieces showed a nice gap at the edges to butt weld the length. Not necessary to weld the inside,although he did, because I wasn't clear enough when I left it. I cleaned the inside up with a carbide burr and wd40. I was more clear when I left the lid pieces. It cleaned up easily. The lid fits over the box like a shoe box. We welded small 1/8 tabs just down inside the box, to accept SS 10x32 button head screws through the lid. I later removed one to get the battery to fit in. (glued in a fake screw head!) I put the box into the triangle and tapped it forward tight onto the water bottle rivnuts, I had installed two new ones to mount a shark previously, so I had a good spread and 3 holes. Mark a scratch beside the rivnuts. removed the box and drilled holes in the center of the box at the scratches. Counter sunk and installed box and bottom screws, Centered it at the top tube and drilled a small hole through the box and the top tube, then installed 2 rivnuts there. Here are some pics. We can do it! It's very light and strong. It looks great with the other aluminum parts of the bike! I think I will use steel next time and weld it myself and save a lot of $. Paint would be fine.
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I think welding would have been less expensive if it was on the outside only. It was unnecessary on the inside and my fault for not being clear to the welder. e-rod -
That is superb work. You should consider powder coating it. Your local powder coater can match the blue color of your frame.
Very well done. You have lived up to your name, e-rod! using aluminum was the right choice for saving weight.Last edited by commuter ebikes; 10-26-2016, 08:22 PM.Comment
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Thanks for the nice reply commuter ebikes. This bike is so much fun to ride. Battery weight is in the right place and feels nimble enough at close to 70lbs with two batteries and gear. The 24ah GA has a lot more power output then the ncrb shark. But with the shark as a reserve, I can go visiting all over these hills and still get home! Happy Motoring, e-rodComment
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Give this guy an award for proper distribution of weight!Comment
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That's great, thanks for showing it to us. Well protected, easily locked up.Fabrication is fun! Build something today. Show someone. Let them help. Inspire and share. Spread the desire.Comment
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Hi e-rod,
Excellent work and great pictorial and description. The pictures are super helpful b/c I am now debating ways to secure a battery on an upcoming ebike build (see my question here ). Why did you chose to move from a clip/lock shark battery to one enclosed in a secure box in the frame? Was it for security, looks, other? Thanks!Comment
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Hi, Ponjocat, thanks for the reply. I built the box so I could expand my range by adding a large battery. I live in a mountainous area. I had it strapped in the frame for awhile, but it was going to get wrecked because it didn't fit very well. The box was the only way to safely carry it. I moved the shark to the underside of the frame. I carry them both when I'm going on a long ride. the weight is low and acceptable. When the big one gets low, I change the plug to the shark. The shark locks on with a key, and I use it, so it won't bounce out of the mount I think that it's safe enough, although you could probably kick or pry it off. but that would wreck it. I used button head screws for the box, a thief would need the right size allen wrench. You could fabricate a lock into the lid as well. I haven't gotten there yet. Happy Motoring, e-rodComment
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Made mine out of 1/4" plywood. ($5.00) Not quite as fancy as e-rod's but it works! I even did a $5.00 paint job on it. (Don't be fooled by the "750" watts designation. That's only there for anyone thinking I need one of their permission slips to have a 3,000 watt machine! Now I need to figure out a better locking system.Comment
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