DIY replacement battery pack for bike lights

soundwave

Esteemed Pedelecer
May 23, 2015
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case
http://www.ebay.co.uk/itm/152101697909?_trksid=p2060353.m1438.l2649&ssPageName=STRK:MEBIDX:IT

batts
http://www.ebay.co.uk/itm/191955071986?_trksid=p2060353.m2749.l2649&ssPageName=STRK:MEBIDX:IT

charger
http://www.ebay.co.uk/itm/Nitecore-D2-LCD-Li-ion-26650-18650-16340-14500-AA-AAA-Universal-Battery-Charger/162193614313?_trksid=p2047675.c100011.m1850&_trkparms=aid=222007&algo=SIC.MBE&ao=1&asc=38837&meid=35da77b7e0b84ec79c60b88b78f19d22&pid=100011&rk=3&rkt=10&sd=322232541505





after 5hrs of use with the light on setting 2 and a 5v fan 500ma it had 3.46v left from 4.2v fully charged and 1 bar out of 3 on the pack still lit.



the pack also has bms to cut the voltage from the lowest cell in the pack.


the pack does put out 8.4v fully charged from the light cable so make sure the light you use can handle this or you can use one of these to up the voltage for say a 12v light.
http://www.ebay.co.uk/itm/321512279591?_trksid=p2060353.m1438.l2649&ssPageName=STRK:MEBIDX:IT

the spec of the cells says you can take them down to 2.5v but to get even more life from the cells id recharge them at 3.1v as after that the voltage falls of a cliff anyway so give them a more easy life.

these are the same cells Tesla use in there cars and the only cells better are NCR18650G at 3600mAh but you cant buy them anywhere as Panasonic cant make them fast enough for Tesla.
http://www.ebay.com/itm/Tesla-Model-S-battery-module-24V-250Ah-5-3kWh-444-Panasonic-18650-3400mAh-/262333679871?hash=item3d144e48ff:g:OSkAAOSwh-1W5acD&vxp=mtr

see here for the real spec for the cells
http://lygte-info.dk/review/batteries2012/Common18650comparator.php

so as long as you dont over charge them or drain them lower than 3.1v they should last for years if not a decade or more, if not using them then charge to 3.6v and just check them now and then and top up if needed.