18650 eBike battery pack - 10s4p

thingiverse

My attempt at making a smaller battery pack for a 36v eBike diy build to sit as low and forward as possible. These designs are specifically for my 2017 Nashbar Flat Bar Road Bike but you may find something useful for a remix. The colored image shows the parallel groupings for wiring purposes. To save on cleanup/post processing, print with a skirt instead of using a brim. Depending on battery selected, this size should provide about 18-25 Miles of range depending on calculator used and cells chosen. Including 1 unit for the battery cell holder with the modified sides to avoid using supports during printing to use as a building block for other projects. It is not intended to print and snap together but to model it in tinkercad via importing the object and duplicating it. I designed the battery mount to be installed over the forward bottle holder. I'm expecting to utilize stainless steel hose clamps to hold it in place so I shouldn't need the original bottle mount screws. I hope to have the hose clamp screw face inwards but it's not a requirement. The through hole should allow mounting the clamp in either direction. V2+ Items are slightly longer to fit the finished battery better because I was having trouble getting the battery pack into the box on my first try. I added a groove in the battery mount to allow room for the battery cage and provide space for the BMS which I expect to strap to the top of the cage. Some added height in the box can be helpful but not absolutely necessary. The box top will need 4 nuts inserted at the corners to accept a 5mm bolt. It's supposed to fit over the battery mount and be secured by 4 5mm bolts of appropriate length with a washer on the mount side. (This will need supports everywhere, not just touching the build plate) but you can play around with the print orientation to see what works better for you. Plan to pass an xt60 connector through that hole. V3.x Box top squares off the bottom edge to keep some extra space for wiring.The box fitment was too snug so I added some additional height to the box for breathing room but maybe still not enough space for shrink wrapping the battery pack The "controller mount" is just something for mounting the kt36 controller. It's ugly and a semi enclosed box would work much better but until I come up with an alternate, the parts for holding the controller (V1_x) are intended to mount somewhere convenient. The various pieces are supposed to be assembled with the printed dowels coated in epoxy prior to insertion with the excess length trimmed flush. The controller parts can be expanded slightly to fit the controller shape better since it's a tight fit especially the bottom piece where the controller sits and the wires pass through. "Misc Wiring and Dash" mounts to the handlebar mount. 1 piece mounts on the underside for routing the wiring and the other piece mounts above the bar to center the 900s LED display. "Wiring guide" is a guide for cable management to run the wires under the top of the frame and even down the back vertical. Print as many as needed to tidy things up. The Guides secure with a zip tie or just tape the wires directly to the frame if that's easier. Included in that file is a part to mount 1 small motorcycle brake light such as this one: https://www.walmart.com/ip/4Pcs-Flowing-Motorcycle-Indicators-Flashing-Motorbike-Turn-Signal-Lights-Rear-Brake-Lights-Width-Lamps-12V-Universal/1868270923 After completing the build and taking the bike for a few rides around the neighborhood, I can say that the build was a success. Although I'm not happy with the how the battery appears to be huge relative to the size of the frame I am looking forward to finalizing the box either with a revised setup or just using a slightly taller box to enable it to properly seal. I also need to come up with a way to hide all the extra long wires that came in the kit which could mean trimming the wires or just having a box to hide the bundles.