2 cell Flat Top voltage booster

thingiverse

This version of this bike battery is in final release - there may be a Version 2.0 out but not anytime in the foreseeable future. The 48 volt version of this e bike battery requires a 3d printer with a bed size of 287mm x 104mm x 25 mm tall. You probably will not be able to rotate it and print it 104mm x 25 x 287mm tall – It doesn't work that way , the sides will need a ton of support and making the sharp right 90 degree turn in midair will definitely fail. The 36 volt version of this e bike battery requires a 3d printer with a bed size of 233mm x 104mm x 25 mm tall. Rotating the print is also not recommended The 2 cell voltage booster pack is relatively small and can be printed on almost all 3d printers. It's size is 104mm x 86mm x 27mm . Rotating the print is also not recommended Note – Most 48v Chinese e bike controllers have 61 volt capacitors in them – this means at 61.1 volts they will most definitely break. Over - volting a Chinese 48 volt controller is only advisable 2 cells past 13s ( 13 cell in series ) for a total of 15s ( 15 cells in series ) . This means a 48 volt battery and a 2 cell voltage booster is the most currently supported by most 48 volt Chinese controllers for over - volting. This being said – We offer no such warranty of any kind. Lithium batteries are dangerous and should be treated as such . Short circuiting lithium batteries can lead to combustion and smoke inhalation . We offer and imply no such warranty to this product . We hold no liability to death , fire , shortage of life , damage to structure , damage to property , etc . It is advisable before you start to make a plan . This plan should include which parts you will print and use and what parts you need to buy online. The bike frame clamp might not work for certain frames ( We are in the process of acquiring more bike frames and making different frame clamps available) ; Should the frame clamp not work for the type of frame you have you will not need the DIN rail adapter , the frame clamp or any hardware for those 2 thingiverse pages. You would also not the din rail clip & two m4 x 20mm machine screws listed in Required Hardware on this page. The 36 volt and 48 volt batteries can use both button top and flat top 18650 cells , however to switch from on to the other you will have to change the contacts . Flat top cells are more readily available with cheaper options and great capacity . Button top cells offer more safety with some cells having integrated circuit protection or built in fuses – this can be important to safety . The cost for button top cells can be up to 5 – 10 times more for the cells over flat top when it comes time to buy the lithium batteries. Parts kit available here - https://www.ebay.com/itm/384804097590 ( sans printed plastic parts and 18650 batteries) Required Hardware The internal 18650 battery contacts are made by this company - https://www.keyelco.com/product.cfm/Slide-In-A-Battery-Contacts/5215/product_id/14452 You'll need 2 - Mating Spring Contact: Part Number 5222 1 – 2 Cell Spring Contact, A Cell, 18650 Part Number 5215 All 3 of these parts can be ordered from either Mouser or Digi-Key by clicking the link “ Check Distributor Stock” on each part number page on keyelco.com and then clicking the shopping cart on either mouser or Digi-key . You'll also need 1 - power connector of your choice with at least a 3 1/2” pigtail (xt60 with pigtails recommended ) 2 – M3 20 mm wingnut screw 2 – M3 wingnuts 2 – Flat Top 18650 batteries . All the same brand , style , make and capacity. To mount the battery to the frame grip you will need the following 1 - DINM23LR DIN Rail Clip from https://www.winford.com/products/dinm20.php 2 – M4 x 20 mm Phillips Pan Head Machine Screws Assembly Watch this video for assembly instructions. https://www.youtube.com/watch?v=UpSmjdgJ4Ko Sponsors I would like to thank Winford Engineering , Keyelco Electronic Components Corp. and BoltDepot.com for contributing to the success of this project . Thank You ! We could not have completed without your generous help ! https://www.winford.com/products/dinm20.php https://www.boltdepot.com/ https://www.keyelco.com/category.cfm/Slide-In-Battery-Contacts/Slide-In-A-Battery-Contacts/p/1039/id/1224 California Filament donated a ton of PETG filament and also educated me about PETG. https://californiafilament.com/collections/petg This eBay store sold me the solder seal connectors at discount rate. It is not a bad price and service was quick. https://www.ebay.com/itm/384643398844 Should you not have a 3D printer or not have one large enough for this print , the doors are open at my friends print shop on treatstock.com . Here's the link to his profile .He has printed about a dozen of these flawlessly. https://www.treatstock.com/c/shellback-workshop He is quick and knowledgeable and has good service . I'm sure he can get both halves printed and shipped priority mail to you for less than $50. Also I'd like to thank Sheldon Grant at Project3dprinters.com for mentoring me and proving me with 3D printing services . I will have some part kits ready on eBay possibly in April 2022 ( I make about $1 off the parts , for those of you curious , the intended design of the parts kits is to keep those interested from having to buy quantities of 100's of parts when only 2 or 3 are needed, at $11 a parts kit I think your savings are about $39) Also keep an ear out for new bike clamps as we find a style to support your frame ! Be kind ! Tip please !