E-Bike Battery Bottom Cover Replacement

thingiverse

This is a replacement component for a cylindrical e-bike bottle battery case featuring contacts at the bottom.\r\n\r\nCautious Note: soldering, crimping and other advanced electronics skills are necessary to replace the part. Proceed with caution!\r\n\r\nI fabricated the case using PET-G to provide enhanced heat resistance and stability. ABS could be even more effective, while PLA may cause the areas around the contacts to melt or deform.\r\n\r\nA second version without rounded edges on the bottom is also available.\r\n\r\nLayer Height: 0.16mm.\r\nInfill Density: 40% (I added 100% infill sections around the contacts in Cura)\r\nSupports: none (with PET-G, otherwise "everywhere", to support the holes)\r\n\r\nThe contact points are comprised of M6 bolt heads that were flattened and shortened using a grinder before assembly. They were connected to 2.5mm^2 litz wires via lugs. I added washers above and below the lugs, ensuring the screws weren't too long so they wouldn't protrude from the nuts. The nuts were secured with a drop of hot glue.\r\n\r\nAll other components are sourced from the original battery case: switch, plug, fuse, and screws for closing the case. Old solder, adhesive, and sealing must be carefully removed before re-use and replaced reasonably when combining parts again.\r\n\r\nPrint the model for the seal with a soft filament like TPU. This is the seal between the bottom and the metal case:\r\nLayer Height: 0.16mm.\r\nInfill Density: 100%\r\nSupports: none\r\n\r\nCautious Note: the battery operates at high current levels. Disassembly and assembly should be performed by a person with certified electronics technician skills. Regularly check the part's integrity. Use this part at your own risk!