reptilian

I tore open my duct taped battery yesterday to fix a connection. I would like to built a case for it to mount onto my frame. I need to make something that will still leave access to the battery, since I can not always charge it were the bike sits.

Does anyone have any suggestions? Materials?

I was thinking acrylic would be best, but how thick would it have to be to hold up? I don't really want it to be see threw either.

snowranger

Hope you were able to fix the bad connection. I made my case out of 1/4 inch plywood with butted joints, all glue fastened. Weighs 1.5 lbs. It has a hinged lid and a lockable hasp. The case has a switch that allows for either charge or discharge. I can remove the battery from the case by unplugging a few of the anderson connectors and lifting the brick with webbing that is around the battery. Since I changed over the charging plug to andersons, I can charge the battery through the switch or to the battery directly.

unime

Acrylic is too brittle.

PVC (commonly used in plastic pipes) comes to mind as an alternative. Like acrylic, it can be glued together. You'll probably have to paint it unless you can find a UV stabilized product.

Polyethelyne (HMPE ot UHMWPE) is a nice plastic to work with, but it cannot be glued. My LPS (local plastics shop) sells a black version, which might work even though it is not UV stabilized. Marine grade sheeting is available, but pricey. If you decide to screw together UHMWPE, be sure to drill pilot holes the same size you would use for tapping - this is a high-strength material that does not give (nails bounce off of it). Just my two cents. Let's see if anyone can come up with a better suggestion.

cerewa

you could try heavy shrink wrap. That's what they use on a lot of RC batteries and it's also what they use on YESA lifepo4 e-bike batteries.

reptilian

Im just gonna go with 1/4 wood for now. my budget is a little tight at the moment