How I skinned my electric bike battery box part 2

March 18, 2010 · 4 comments

This video is a continuation of the battery box fabrication. It shows the lid fabrication that has lots of angles, bends and notches. It turned out really nice I think.

My new press brake tool worked out really well. I used it to bend the sides of the lid.

The next and the last video will show how I solder the internal charging connector and install the batteries.

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To see part 1 click this link.

{ 4 comments… read them below or add one }

1 samh March 18, 2010 at 10:41 am

Coming along nicely! One question – are you planning on a rear fender? If not, it looks like tire rotation would direct spray directly into the space between the side and the lid.

2 Dan March 18, 2010 at 10:56 am

Thanks Sam. Yep, put the fenders on yesterday. Good observation about the space under the lid. I think I’m going to leave it that way for now. I could close the gap with more sheet metal but is probably alright the way it is. I think most of the water will stay out now that the fenders are on. I put drain holes at the low end of the box so any water that gets in there won’t stay.

3 Pete Prebus March 25, 2010 at 11:45 am

Great Video! I like that aluminum bending tool and the cat supervisor.

4 Dan March 25, 2010 at 7:08 pm

Thanks Pete. I have big plans for that bender if the cats let me us it.

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