BAC8000 Controller Cover for Sur Ron eBike

cults3d

This is a 3D printed BAC8000 controller (an ebike/electric vehicle controller) cover - designed to help keep out dirt, mud, salty water, etc. NOTE: You need to remove some plastic from at least 2 of the fins on the back of the controller (that separate the various terminals/leads). This had to be done due to the way the controller is mounted to the bike. NOTE 2: Once everything is together, you'll want to plug the screw holes (where you screw in the bolts that hold the wires down) with the cover caps and then seal all edges on the sides and gaps between the cover and wires with something like liquid gasket or liquid electrical tape (to make sure no water gets in). Other instructions: I recommend printing with a 0.8mm nozzle, as this will make the cover much stronger. After 3D printing the cover, apply a coat of resin to the entire thing - on ONLY the outside - do not coat the inside. Once that is finished curing, apply another coat and let that cure. You can apply a third coat if you want - it will help to make sure it's waterproof and increase the strength of the cover. Feed the wires through the cover and hand tighten them onto the controller (or you can tighten them fully). Phase wires should come in through the bottom and the positive and negative battery wires should come in through the side (at kind fo a 45 degree angle) Snap the cover into place on the controller. Tighten all bolts. cover edges and gaps between controller, wires and case with liquid gasket or liquid electrical tape. Mount controller onto bike. That should be it! Your controller terminals will now be protected from dirt, mud, water and especially nasty salt water (from salted roads) - which is conductive and can short out the terminals! If your phase or battery wires aren't fitting through the case, use something like a soldering iron, exacto knife or a dremel to make the holes slightly bigger (or measure your wires and modify the STL beforehand).