DeWalt Drill Battery Mount for Electric Skateboard (+anything else)

cults3d

These budget-friendly DeWalt contractor batteries are actually 5S2P of Panasonic/Sanyo NCR20700A cells, with each cell rated for a continuous discharge of 30 amps. Use them to power your 10s electric skateboard to fly with 60 amps at a fraction of the cost of some pricier 'Tesla Cells' packs. Or build your own unicycle, eBike, or 1000W LED system - anything! Why risk tearing apart and harvesting the cells when you can use the packs as-is? Follow this project on hackaday.io! The 3D printed mount is designed in OnShape, a web-based free-to-use GitHub of 3D modeling (a SolidWorks compatible clone). It's modularly designed and easily forkable for your own project. It's designed to be printed on small 3D-printers with an optional dovetail connection in the middle (for the skateboard mount). It prints perfectly in PLA (or even PETG) with 8% density, 80% overhang support, and 25%+ infill. No finishing is required, and it fits perfectly with the batteries. Details The source! This file on OnShape! Remix and use derived parts to your heart's content! There are four main tabs: Battery mount - the basic, no-frills, single mount. No attachments at all. All of the next tabs use this as a 'Derived Part' and the foundation of their designs. Underside mount. This was my original design for my Wowgo Skateboard and works great with added support ribs! Without deck-risers, battery clearance isn't really enough, so I created the: Topside mount. Perfect for adding ~12 miles of range and/or 60A capacity to an existing board or replacing your existing battery altogether. This design includes 5.5mm eyelets for alternative mounting, perhaps to an eBike with a buck boost controller. Duo mount. A simple back-to-back mount designed for non-skate uses. I use a 3D-print of this for charging – and break out the cell-balance pins. Stacked mount hasn't been printed or tested yet. It's designed for flexible PETG plastic and moves the batteries far forward on my Wowgo deck to help with clearance issues from the ‘underside mount’. I'd like to add more! Send me photos with measurements, and I'll help fit it to your board and/or feel free to fork the design and modify yourself! Post here with your results! Skip downloading these STLs here (unless you've got my exact skateboard or want a charger-mount). Go fork that OnShape design and either modify away or start fresh, including the 'battery mount' as a Derived Part. Printing Each part can be printed on small 3D-printers like my little $200 Monoprice Select Mini. The larger underside and topside mounts have a dovetail connection that works great without glue to hold things together. All pieces print perfectly in PLA (or even PETG) with 25%+ infill (I use 30-35%). All parts that are printed flat (all but the 'duo mount') need overhang support, I've liked just 8% density, 80º overhang. Building Required bits: The batteries! Here on Amazon (direct link, no affiliation). Industrial Male Disconnect Vinyl 10 Blue(34529) from Ace hardware. I bought mine at my local ACE hardware. That’s it! Crimp the connectors with some beefy pliers or a real crimper. They friction fit into the mount with the help of some normal pliers. Useful References: Battery teardown and details: DeWalt 20V Max 6.0Ah Pack Teardown & Analysis Another similar project to this one: DeWalt Flexvolt 60v Battery Adapter Again, the CAD source on OnShape This project on hackaday.io Gfycat octolapse timelapse of me printing the duo mount (and running out of filament at the end)