Bike light LiIon battery pack holder

youmagine

There are some pretty great affordable bike lights available on eBay, but they have one major disadvantage: their battery packs aren't waterproof. They're simply shrink-wrapped and tossed into a cheap nylon bag. This design, however, holds a standard 4-cell 18650 pack - the most common type. The SCAD can even be modified to accommodate other sized packs. It comes with a strain relief for the wire that has a kink in it, allowing you to crimp the wire so that a tug on it won't rip it loose from the battery pack inside. Additionally, it includes a pair of rails that will keep the pack centered on a bike tube. To assemble: Print both halves. To make a printed object waterproof, apply acetone to its outer surface using a cotton swab or brush. Note that this may cause white spots on the object, but after three attempts, they were pretty much gone and the object was waterproof. Insert your battery pack with the lead exiting the case along the strain relief end and test fit it to make sure everything works. You might want to add some padding if the pack is loose so that it doesn't rattle around. Apply silicone sealant along the seam, being generous, especially at the wire exit point, and secure the lid with self-tapping screws. Press the strain relief tightly together to crimp the wire. Wipe off the excess sealant and wait for it to cure. You might want to cement a bit of old inner tube or other soft material over the rail side where it will touch the bike frame to keep from marring it and to keep it from rattling. Thread a velcro wrap through the holes on the side. Enjoy!