So, since there seems to be an international interest in the eBike batteries I’ve built for myself and friends I’ll post some pictures of batteries, cases and give a bit of insight as to how I’m designing the cases.

I’m thinking I’ll make one post for one or a couple of batteries. That way it’s easier for me to post something a little now and then, and it won’t be a massive boring post of all of the batteries and iterations I’ve built and taken apart. 😉

So, enjoy, or just skip to something else!

So – one of the first custom batteries I built was for my brother.

So, of course there has to be a logo on the case, but since we couldn’t figure out what to put there he got the standard.. 😉

This is a 52V 14s7p battery with LG MJ1 cells making it a whooping 24,5Ah and almost 1,3kWh – which is insane for an eBike!

As you can see there’s the cell frames into which the MJ1 cells are mounted and welded. On top of that there’s kapton tape to protect the connections from shorting out. Then there’s a frame – a Joiner I call it since it joins the two cell frames together. On top of that there’s a TPU gasket to make the battery a bit more waterproof, and then there’s the top piece.

After adding the balance leads I used proper electrical tape to further insulate and protect the cells – something I’m not doing anymore since it makes the size of the battery too hard to predict. Also adding more kapton gives a better protection and a neater size.

The battery mounted in the frame of his Radon bike, propelled by a BBSHD motor. At 70A continous power output this battery is pretty oversized for the application but it gives a good range.