No weld battery pack

thingiverse

I've been wanting to convert my vintage Cannondale aluminum hybrid bike to an ebike but with only minimal changes and using a design that did risk the integrity of the aluminum frame. No stress on either the front forks or the rear drop outs. I thought I'd have to design and build my own friction drive and was well on my way to doing so. However, I am also a minimalist. I like to reuse and salvage items whenever possible rather than buying new. One day when surfing salvage and recycling centers online I was lucky enough to find incomplete friction drive conversion kits from a Canadian manufacturer (Alizeti) that apparently went out of business. Sad for them, lucky for me since I was able to acquire 5 incomplete kits consisting of the motor drive, the mounting frame and aluminum extrusion battery housing. https://youtu.be/BCANNwzta6Y The units come with the main circuit board and bluetooth board, but without the controller that is needed to make the boards work together. The kits are also missing batteries. IIRC they came with one battery module with an option to buy a second battery. I can make these drives work using a different motor controller, and I can even make the friction drive arm raise and lower using simple circuit. What I really needed were batteries. Since the kits use a really good extrusion as part of the mounting system I needed/wanted to keep the extrusions so I designed a weldless system to join sixty four 18650 cells into a single 8S8P battery pack. So here is how I am doing it as I make them. I'll update as I complete portions of the construction.