Cheap Lipo4 from China

[jbond]

best to build one out of ply.

Ply has the advantage of being low tech and easily made with hand tools. Maplin do a bunch of enclosure acccessories with things like corners and locks. And vinyl covering is easy to find. Many many years ago I made a vaguely portable case for a BBC Micro and a 9" monitor like this.

I'd be tempted to make something out of bent and pop riveted aluminium sheet. But it's hard to get a good finish without the proper tools. You really need access to a big guillotine and folder. If you can find it, there are some plastic sheets around now in a plastic that can take permanent bends with a hot air gun. That might be another option.

 

[flecc]

Ply construction can simulate a metal or plastic case with curved corners, I once made a cassette recorder deck top plate in this way and no-one believed it wasn't moulded until I lifted it off and showed the wooden underside.

The technique is to produce the ply box with internally braced corners which are then rounded externally. A thin car body resin filler is then used to seal the ply surface and fill minor crevices etc and the end result rubbed down as if repairing a car body defect. Finally the case is sprayed with cellulose silver from a repair aerosol, allowed to harden for a couple of days and finally finished with clear lacquer car aerosol spray.

I lengthened an eZee bike battery case with ply sections to take extra cells, the case cut in two, separated with the ply strips which were resin moulded into place and the whole finished as described above. You can see the end product alongside a standard eZee battery case in this photo from which no-one would guess that it wasn't a genuine article:

 

[onmebike]

I spent quite a while the other night looking for a project box that would take this battery but didn't succeed.

I think to allow a little foam packing around the battery then a box for this particular unit would have to be 230x160x120 as a minimum. What I found were generally OK in 2 dimensions but way out in the other.

All that said, has anyone found a sensibly proportioned box for this battery?

........ I had concluded what someone else had said (I think it was Old Timer) and that was it was best to build one out of ply. That's what I'll do. I'll paint it and tailor make a canvas cover for it.

You'll find one 240x160x120 on this site's listing, scroll to bottom of page. Part No CEM 241612*.
.

CEM Series (Plastic Enclosures)

 

[aseb]

I looked at these options also spending months searching, even got as far as buying a large plastic toolbox to do the job when I came across something better. My battery is 200 x 140 x 160 mm and I got an ABS plastic topbox which is lockable, your battery would would fit in it too (not at the same time though!). This is the third one I'd tried, first was from eBay somewhere in Yorkshire and although the dimensions given made it seem as if it would fit the curves wouldn't allow it- refund no problem- yours may fit in it. 2nd one tried was ok but the bottom isn't flat so sits (to my mind) too far back on the rack- advert picture seems very carefully taken so this isn't noticeable. Bike blew over in strong winds and cracked plastic near a hinge (repaired it no problem, + don't trust the centre stand when it's windy because of high c of g because of battery) but i looked around for something a bit better and found a topbox the same as the 2nd one but with a flat bottom (both box lids are the same, only the base is different) so I could sit it a little further forward with weight over the axle rather than behind it- quick look on ebay brought this up- looks the same, but check the internal sizes are suitable for your battery, and he doesn't give external dimensions, and whether the bottom is flat if that's important to you.
There are other motorbike top boxes that will take the battery but most are wider than long- if that's ok for you there should be more choice, but many seem to curved meaning a large box to get a fit.

The lock is cam lock affair which bears onto plastic so wouldn't be too resistant to forcing, I beefed mine up with a shaped piece of aluminium which is bolted into place (the second one I'd tried got broken into while parked outside a supermarket in Blyth, this one has either resisted attacks or been luckier). I've also drilled through the back and fitted an led light to it. I can try and get a few pics if you'd like (phone pics unfortunately, haven't seen my digital camera for months and months). Plastic is pretty thick and tough, and it does a good job with enough room left for the controller, hat, gloves, a few tools, and the 1.2m 10mm cable that came with my Magnum Plus U-lock.

Update:
curved bottom one on amazon
flat bottom one on amazon

I just noticed the ebay link is missing- strangely it does show up on my message in edit mode. Anyway another try- ebay one

 

[jbond]

http://www.pedelecs.co.uk/forum/electric-bicycles/4769-diy-stage-5-prepping-fitting-electricals-photos.html#post60345

daniel.weck got a 36v10Ahr Ping battery (150*150*105) in a 100 CD flight case. The key seems to be that the 150*105 dimension is close enough to a CD jewel case. The trick then is finding CD flight cases where the CDs are stacked in one long row. For a 36v15Ahr, I think we need a 120 or 150 CD case. This one might work.
120 CD DVD DJ ALUMINIUM STORAGE CASE & SLEEVES BOX on eBay (end time 03-Dec-10 16:45:00 GMT)
or
Hama Aluminium CD Case for 120 CDs incl. Sleeves: Amazon.co.uk: Electronics

 

[Cyclezee]

For a 36v15Ahr, I think we need a 120 or 150 CD case. This one might work.
120 CD DVD DJ ALUMINIUM STORAGE CASE & SLEEVES BOX on eBay (end time 03-Dec-10 16:45:00 GMT)
or
Hama Aluminium CD Case for 120 CDs incl. Sleeves: Amazon.co.uk: Electronics

The 120 CD case isn't quite big enough as the battery is 240 mm long and case is 230 mm long.

I found a couple of these boxes in my shed.

​

They were originally used for transporting anatomical plaster models and alginate impressions. Made by DBI Plastics in Denmark, part no.DK-4295 and came in a variety of colours, but I don't think they are available any longer. The capacity is 4.5 Litre and internal dimensions are 265mm x 160mm x 110mm.

These might also do the trick Coleman Cooler 5l Blue - Johns Cross Motorhome and Camping Equipment#, I used them for the same purpose. If I can find where I put them , I will post the internal dimensions.

J hn

 

[averhamdave]

Well its turned out to be a really interesting thread! Particularly the "box options".

It'll be a while before I need a box for my project bike but the choices are growing by the hour!

Plywood homemade box
Bicycle TopBox
Plastic electrical enclosure
CD storage box
Caravan Cool-Box
Some sort of medical transportation containers

My favourite is probably the ABS plastic enclosure providing I can get one sized correctly. It's waterproof, neat and relatively secure. I can fix an ignition key barrel, LED, charger and battery output sockets to it properly and neatly.

Any other suggestions? Some pictures would be nice.

 

[Old Timer]

I had some very dry and light decking( not the heavy duty type) it was very light. Thick enough to screw together and the larger two sides were in ply. Very light construction and made to measure. Painted mat black and fitted with 4 screw in dowels (wood screw- M6 thread)for one side as a lid fastener with wing nuts for easy removal in case of fire

The nice thing is it wants to grip the rear rack being timber and the wing nuts on top give anchor points to keep the bungies in line. I could easily make up plates to fix it to the rack on a more permanent basis but with bungies I can use it on any of my bikes if required. I`ll shoot a picture in the morning.

 

[onmebike]

I had some very dry and light decking( not the heavy duty type) it was very light. Thick enough to screw together and the larger two sides were in ply. Very light construction and made to measure. Painted mat black and fitted with 4 screw in dowels (wood screw- M6 thread)for one side as a lid fastener with wing nuts for easy removal in case of fire

The nice thing is it wants to grip the rear rack being timber and the wing nuts on top give anchor points to keep the bungies in line. I could easily make up plates to fix it to the rack on a more permanent basis but with bungies I can use it on any of my bikes if required. I`ll shoot a picture in the morning.

Come on Dave, it's unlike you not to show pic's?

 

[Cyclezee]

To answer the above regarding my invoice:

The parcel was (I'm sure) delivered by UPS
The invoice is from Fedex

The seller valued the battery at $66us

The invoice is made up of:

"Disbursements out of the scope of EU VAT" - £7.28
"Clearance Administration Charge Vatable at 0%" - £10
"Total amount due" - £17.28

My parcel was delivered by Fedex and I received the invoice from them today.

In my case the seller valued the battery at $60

The invoice is made up of:

Disbursements out of the scope of EU VAT - £6.62
Clearance Administration Charge Vatable at 0%" - £10
Other Charges Vatable at 17.5% - £0.00
Other Charges Vatable at 17.7% - £0.00
VAT at 17.5% - £0.00
Total amount due" - £16.62

I can't really grumble too much at that.

J hn

 

[Old Timer]

My parcel was delivered by Fedex and I received the invoice from them today.

In my case the seller valued the battery at $60

The invoice is made up of:

Disbursements out of the scope of EU VAT - £6.62
Clearance Administration Charge Vatable at 0%" - £10
Other Charges Vatable at 17.5% - £0.00
Other Charges Vatable at 17.7% - £0.00
VAT at 17.5% - £0.00
Total amount due" - £16.62

I can't really grumble too much at that.

J hn

No! and even less when you get to realise the good value

 

[averhamdave]

Thanks ASEB and everyone else. I've decided to purchase a locking top-box for reasons of neatness ans its additional storage capacity. Plus I suspect at £20.33 I will struggle to better it in the value for money stakes.

M-Wave Bicycle Rear Carrier Top Box: Amazon.co.uk: Sports & Leisure

 

[piotrmacheta]

Very interesting thread. I carry my home-made batteries in a Topeak RX bag. It is the smallest one they do that slides and locks into their special racks. It's a neat way to carry/hide batteries and is easily removable for charging etc.
I have made three 48v packs now - one has 3x40 cell 4/5 sub C in parallel (6Ah) (very heavy ~5kg), 2nd has 40 Ansmann racing 4.5Ah (2.8kg) and the 3rd is an experiment with LiPo's used in the RC world - 2x6cell and a 2 cell 5Ahr LiPos in series (14s). In the 2 latter options there's room in the bag for punture kit, pump, wallet and a small lunch. The batteries I've just bought are Winforce 30C packs from Ebay so in theory will deliver over 100A continuously and I have pulled up to 23A and found that the cells have kept their voltage up OK. This 5Ah 48v pack (14S) weighs only 1.5kg and seems to have a range of about 10miles which is all I need as I prefer to carry less weight. The only real problems are charging them and preventing them from over-discharge. At the moment I charge them individually on a Bantam charger with ballancer so that's easy and I have a LiPo alarm on each which sets off a buzzer if any drop below their 3V/cell average although I also have a Cellmeter 8 which will alarm on each cell.
One question I have is does anyone know if I can get a BMS and charger that I can link my 14s total packs to so that I can charge them together and would cut off power at 3v/cell?
PS I have used lunchboxes to hold my batteries in the past - lots of different sizes to choose from!

 

[averhamdave]

Top box arrived today. Little slow delivery for Amazon (12 days) but never mind its here and will be excellent for mounting the battery on my project bike. There will also be a little space left - about a third of the box - for carrying a few tools, waterproofs etc.

M-Wave Bicycle Rear Carrier Top Box: Amazon.co.uk: Sports & Leisure

 

[NRG]

.
One question I have is does anyone know if I can get a BMS and charger that I can link my 14s total packs to so that I can charge them together and would cut off power at 3v/cell?

Missed this, yes see tppacks.com

 

[jbond]

Old Timer (and others). You've had the battery for a few months now. How's it holding up?

 

[bode]

Old Timer (and others). You've had the battery for a few months now. How's it holding up?

Just what I was going to ask, but there have been no replies in six months. Come on, chaps!

 

[Old Timer]

It`s working and charging 100%. A superb battery at any price.

Dave

 

[bode]

Thanks Dave. I was just gearing up to order a Ping battery when I came across this thread, so now it looks as if I'll be getting one of these!

Any comments from any other buyers, e.g. averhamdave or onmebike?

 

[aseb]

Thanks Dave. I was just gearing up to order a Ping battery when I came across this thread, so now it looks as if I'll be getting one of these!

Any comments from any other buyers, e.g. averhamdave or onmebike?

I bought one of the Duct tape wrapped packed (CammyCC, Volgood.. he uses a few names) and was happy with it until I got a Cycle Analyst- the 20Ah pack was only giving out 12Ah.
I wouldn't have known without the means to measure the Ah used in discharging that the CA gives.

And I'm not the only one, others have also had similar issues. There's a thread on the Endless Sphere forum by Amberwolf showing a stripdown (hot melt glue, layers of Duct tape, Card) and repair if anyone is interested.

Mine also has damaged ribbon cables (burned) where they come out of the pack to go to the BMS.

The batteries are the cylindrical 18650's. There are popped welds on several battery connections. Absolutely no support or even replies from the seller but they still sell on ebay and their web site.

I'll replace it with a Ping Battery- he has a good reputation for supporting his product, does answer emails, and has given answers to all my pre-sales questions, even though I told him it will be next year before I buy.