Hailong E-bike battery adapter for Gazelle Orange (Pure)

thingiverse

This is an adapter made specifically for the China Hailong e-bike Battery case, designed to fit perfectly on the Dutch Gazelle Orange Pure bike frame. I didn't want to drill two extra holes in my bike's frame to accommodate two M5 rivet nuts because I wanted to keep my setup upgradable in both battery and bike aspects. I decided to create an adapter that utilizes Zip-ties at the top of the down tube and two bolts on the bottle holder of the frame. The shape of this adapter keeps it from moving, thus preventing excess force on the original bottle holder nuts. My bike's frame was scanned using a iSense scanner to ensure a snug fit. I designed an adapter with space inside to hide all electronics (250W 36V) and cables (motor and PAS), making for a clean-looking install. An adapter is also included if you want to use the original provided electronics box. It uses Stainless M5 screws (two cylinder heads for the Bottle holder mounts, two flat heads for the battery mount) and two Stainless M5 nuts to secure the battery at the top, leaving three mounting points on the battery itself. Two bolts are attached to the frame, and two large Zip-ties are used on the frame at the top to prevent excess force. The ESC box version features a bleeder hole that allows water from rain and condensation to escape. In the end, I printed both adapters, but ended up using the one without an electronics box incorporated. This is because my Electronics had pre-made weatherproof cables that were too long to fit inside the provided box. The wires now run along the horizontal tube to the provided box on the vertical frame, eliminating the need for cutting any wires. If you don't have the EUNORAU KIT but instead a kit with numerous wires coming out of the speed controller, use the adapter with an electronics box incorporated for a clean install.