ASI BAC8000 Controller Mount/Cover

thingiverse

This is a custom case designed specifically for an Accelerated Systems BAC8000 ~90 volt 860 amp field oriented brushless DC 3-phase motor controller, engineered to enable easy external mounting with a secure seal and a waterproof pathway for cabling directly into the Qulbix 140 frame; https://www.qulbix.com/qulbix-products/diy-parts/frame-kits/140-bicycle-frame-kit. It precisely fits the profile of the universal mounting plate accessory, extended on one side to reach the wire port of the 140 frame: https://www.qulbix.com/qulbix-products/diy-parts/controller-shields/universal-controller-mounting-plate-set. Additionally, it features a slot along one side for securing a line that supports my rear hydraulic brakes. The case is split into two parts due to the large build volume of my Mk3s, each half is carefully slotted to fit together and has a dedicated path for a 40mm M5 screw to maintain alignment. Initially, I encountered issues with the bed lifting at the edges, so I extended the case by 3mm beyond the controller and added screws allowing me to use a heat gun on the seam and smooth them together on a flat surface to achieve a perfectly flat seal and bond each half securely.