Mount for PowerSport batteries on Blackhawk lowboy quad ppg.

thingiverse

A mount for PowerSport batteries on my Blackhawk quad wheeled para-glider was designed to replace the original NiCad pack with higher current Lithium motor cycle batteries. The mount clamps onto a 25mm frame tube, allowing the larger but same-weight batteries to be installed in place of the originals. A centre-tapped 24V system is utilized in this setup, featuring new batteries rated at 140 Amps cold cranking. Eight M3 screws and five-millimeter knurl nuts are used to clamp the mount to the frame. To ensure a secure connection, the nuts were tightened down with glue (CA). Five-square millimeter copper was used for the high-current path, while two-and-a-half-millimeter copper was utilized on the 12V tap. Redundant safety measures include two sets of zip ties and duct-taped terminals to prevent any loose components from coming into contact with the propellers. The original batteries had been causing frustration even when new, as they were marginal in performance. This was particularly evident in the fuel-injected motor, which required more electrical power than its carbie counterpart. The inability of the batteries to power both the motor and fuel pump simultaneously resulted in a cold-start external battery being used. With the Nicads no longer capable of cranking the engine, I opted for the new Lithium batteries. Initial testing revealed they work well with the lowboy charging system, although further verification is recommended. The voltage reached 27V during charging, falling to 26.4V overnight.