How I skinned my electric bike battery box Part 1

March 9, 2010 · 2 comments

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This video shows the final steps to the battery box fabrication. I added aluminum panels to the frame. This makes it look really nice and protects the batteries and wiring from the weather. It also makes the battery box look like an integral part of the bike and not like a mad science project gone bad.

The next steps are to solder the internal battery charging connector that will connect the external one to the internal battery charging connector. I could have wired it directly but having connectors allow the batteries to be removed easily.

The final step is to make a lid. This will completely cover the top to make it look complete. The lid is a complex shape and requires bending. I’m saving that for last.

Even though I’m pleased with the way it turned out there are always improvements that can be made for next time. The major improvement I would make with this design is to make it lighter by using all aluminum. Since I can’t weld aluminum yet, I will bolt it together.

I’ll be posting the next videos parts 2 and 3 soon where I wrap this project up.

The video of the battery box frame fabrication can be seen by clicking on this link.

You can read about all the posts on this project by clicking on this link.

If you haven’t already, sign up for my newsletter in the sidebar. I’ll be sending out useful information related to electric bikes soon.

{ 2 comments… read them below or add one }

1 pdxebiker March 9, 2010 at 2:34 pm

Looks good! This build has come together very nicely.

2 Dan March 9, 2010 at 2:40 pm

Hey thanks @pdxebiker. I’m ready to finish this bike and start riding it. :-)

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