Motorcycle Battery box (internal bag hardcase)

thingiverse

I needed a new battery box for my smaller 4-cell battery to replace the massive lead acid battery I had been using on my rebel bike. Obviously, this new box has numerous applications beyond just housing a small battery! After conducting an extensive search, I found a high-quality leather bag on Amazon that matched the style I was looking for, but it was slightly too tall and required some adjustments to fit perfectly with this specific box size. To rectify the situation, I efficiently cut the bag down to size, ensuring it would provide a snug fit around my custom battery box. However, I wanted an additional layer of protection to safeguard my battery from potential damage, as well as prevent moisture from seeping through the leather. Hence, I created this solid inner case solution! To fabricate the casing, I opted for 3D printing in ABS plastic, although PLA could be a viable alternative with some adjustments (keep in mind that it may not offer the same level of impact resistance). To ensure maximum durability, I employed thick walls and substantial infill patterns. Additionally, I drilled holes as needed to facilitate wire routing. The design features a secure-fitting lid and strategically placed drain holes at the bottom to manage any moisture that might accidentally enter the casing. Please note that this is an amateur creation, and I strongly advise against using it for critical applications, particularly when handling batteries. Although I haven't encountered any personal issues with this setup, caution is always warranted when dealing with electrical components. After installing my 4-cell battery inside the case, I discovered there was ample room left over for additional accessories. To secure the battery in place, I employed rigid foam to snugly fit it within the casing. Moreover, I utilized the excess space to conceal a fuse and some loose wires, effectively optimizing the use of this compact enclosure.