DIY Electric E-Bike Battery Build Lithium Ion 36v 20Ah Super Ultra Light Low Cost 7Lbs Under $300 USD Man VS Junk, Justin's Epic Reviews, Daily Videos
Super Light 20ah 36v Lithium DIY E-Bike Battery !!!
Battery total weight with case, wiring, & BMS: 7.156 pounds 114.5 ounces.
Just the batteries weigh 6 pounds. IF YOU ATTEMPT THIS PROJECT, IT IS AT YOUR OWN RISK !!! WATCH ALL VIDEOS FIRST, AND DO PROPER TRAINING. This battery is the lightest 36v 20Ah E-Bike battery that I know of. The next lightest one is much more expensive, and just under 9 pounds. NO spot welder needed !!! I just built one of these batteries myself, that weights 7 pounds (with the casing, wires, and electronics), and the total cost would have been $262.55 if I had to buy the batteries, but I got the battery company to send me these batteries for free, and paid only $32.85 for the charger and BMS. I also got some thermal adhesive and an in line fuse (not required). The chart below I made, shows the comparison of weight, price, and battery type.
Although the lightest Lithium Battery above is 13.2 pounds, I found one online that was just under 9 pounds, but it also was about $800.00. This means that my battery is worth more than any other battery I've found on the market, because of it's weight. I could have removed more weight by removing the plastic cases, electronics, buying plastic spacer holders, and using a spot welder (I don't have one) to connect the cells together, but this would have required more time, more work, and more money. The way I did this, anyone could do it, and for under $300.00
The bike: solar tracker SLB-2000 bike
INDEX:
#1 Techniroux Power Bank 20000mAh External Battery Review https://youtu.be/6UYBeWEc49M
#2 The Plan for the Build https://youtu.be/yyia52BQeZk
#3 Techniroux Power Bank Dissection https://youtu.be/viD492SvMoM
#4 DIY Techniroux Lithium E-Bike Battery Assembly https://youtu.be/tMkQVajCFws
#5 Installing the BMS DIY Lithium E-Bike Battery https://youtu.be/IWIM32AKwE8
#6 Bike Ride, E-Bike Test https://youtu.be/pGaQnvXySE0
#7 LED Light Cycle & Decoration https://youtu.be/NHooHXAOToo
(bonus) Bike Ride without batteries. https://youtu.be/lUGYwVO3eQo
#8 See it all in super fast speed: https://youtu.be/eNpMfA9QTro
#9 Installing Motor Start Capacitors Man VS Junk 239 https://youtu.be/5_rbPmZTrv4
#10 Lightcycle Night Ride Outdoors Pomeroy WA https://youtu.be/SHVm-Q1eXRI
#1 Techniroux Power Bank 20000mAh External Battery Review https://youtu.be/6UYBeWEc49M
#2 The Plan for the Build https://youtu.be/yyia52BQeZk
#3 Techniroux Power Bank Dissection https://youtu.be/viD492SvMoM
#4 DIY Techniroux Lithium E-Bike Battery Assembly https://youtu.be/tMkQVajCFws
Parts List:
Techniroux Batteries https://amzn.com/B01LQ6Q3OI (Free)
BMS https://amzn.com/B01CQXERLQ
1.5A Charger https://amzn.com/B01ABGAGTM
Arctic Alumina Thermal Adhesive 5g https://amzn.com/B0009IQ1BU
#raspberrypi Raspberry Pi Starter Accessories Kit https://www.youtube.com/watch?v=Px-P6ZpVna4 (FREE)
3D Pen https://www.youtube.com/watch?v=iyVwSq9KZvw (FREE)
#EL-AW-05/BLK-10 Devek Synthetic Rubber Premium Grade Electrical Insulation All Weather Tape, Black (1/2 in x 66 ft, 12mm x 20m) https://www.youtube.com/watch?v=4Y6Rp-2GJXs (FREE)
Ustellar Led Light Strip Kit Led Strip Lights SMD 2835 16 4ft 5m 300 Leds Non waterproof 12V DC Fexi https://www.youtube.com/watch?v=wdVZpzG-U7w (FREE)
#washitape Decorative Craft Masking Washi Tape Set of 12 Rolls Gold Black White and Silver Japanese https://www.youtube.com/watch?v=TKfPNWDVmF8 (FREE)
Other Items I use:
#BicycleMirror Ohuhu Bike Helmet Mirror Bicycle Mirror Cycling Mirror https://www.youtube.com/watch?v=HDYPc9z84OA
#Leedemore Bike Pump, Aluminum Alloy Mini Portable Bicycle Frame Pump, Compatible with Prest https://www.youtube.com/watch?v=weVKkAehQOQ
#BX550 Night Provision BX-550 USB Bike Light https://www.youtube.com/watch?v=ALhVo410xP8
#UnisexOutdoorTouchCyclingMountainBikeGloves YUEDGE Unisex Outdoor Touch Screen Cycling Mountain Bike https://www.youtube.com/watch?v=x9UByrzAwr8
#BluetoothSpeakerswithBicycleClipandSuctionCupBase Bluetooth Speakers with Bicycle Clip and Suction https://www.youtube.com/watch?v=AtiMV9NFGxE
#Tedgembikeclockblue Philonext Bike Lock Cable 4 Digits Combination Cable Lock with LED Light https://www.youtube.com/watch?v=rwsWYwlF350
#thebrightoutdoors Bright Outdoors LED Safety Light Flashlight Red & White Lights for Running, https://www.youtube.com/watch?v=hQtOzgVZzr8
#balaclavafacemaskwintergames Ski Face Mask Sports Neck Warmer Balaclava Jill Up https://www.youtube.com/watch?v=goX7SUwiw9c
#promotion Fit Over Glasses Sunglasses by Great Pick: Polarized Plastic Glasses to Wear Over Regular https://www.youtube.com/watch?v=NXWN4UFuWOM
My Electric Bike https://www.youtube.com/watch?v=S5XXo61R6No
#5 Installing the BMS DIY Lithium E-Bike Battery https://youtu.be/IWIM32AKwE8
I had to print 4 - 5 layers of plastic using the 3D pen, and then I squirted it threw these holes you see here, and hardened it, and then put plastic on top to make rivets as seen above. I also put plastic around the upper corner to make sure it was held in place. So far the plastic seems non-conductive, and everything works well.
#6 Bike Ride, E-Bike Test https://youtu.be/pGaQnvXySE0
During the TEST RUN, I discovered that the Hub Motor on the bike has a speed limit, and shuts off after you get up to 20 MPH, it also won't go unless your already moving at a decent speed. It will start and shut back off if it's not already moving. Thankfully the motor only has two wires. Maybe some day when doing maintenance on the Hub Motor (difficult to take apart) the speed limit can be bypassed. Because the motor is under 750 watts, it doesn't climb hills on it's own and requires peddle assistance, however it does go up shallow hills on it's own. After a 17 minute test ride, the batteries didn't seem discharged.
I
learned that you should plug the charger in to the outlet, before
plugging it into the bike, otherwise the power from the bike goes
backwards threw the charger, and there's a spark. Also you can't leave
it off and plugged in for the same reason that it will discharge.
#7 LED Light Cycle & Decoration https://youtu.be/NHooHXAOToo
At first I tried using a 24-36v step down to 12v 5A converter, but the converter used so many AMPS that my BMS decided it was too hard on the batteries when I turned on the motor at the same time. I didn't blow the 20A fuse ! Apparently the BMS can detect when the cells are too stressed, and shuts down right away, and doesn't come back on for at least 30 seconds. I removed the converter, and hooked up a small 12v Lead Acid battery instead. The lights on the bike draw .5 Amps at 12v, so I should have no problem keeping the lights on. I have some other cool 12v ideas as well. After the BMS shut down and I thought the fuse blew, I decided to decorate the top cover of the battery with the Decorative Craft Masking Washi Tape. This tape is just paper tape, and isn't waterproof, so I used some window shrink plastic, and double stick tape, and then shrunk the plastic with a hair dryer. The results look very impressive, and I can still take the battery apart to work on it. I also re-attached the battery meter / headlight on the bike, and realized that the horn doesn't work, but at least I have a battery meter. I need to replace the 36v bulb, with an LED bulb.
I discovered that the copper connections on the Ustellar Led Light Strips, can not be soldered to with normal solder. I did find some solder joints with solder on them every so many feet. (sometimes in the middle of a strand I cut) so I soldered the wires to these pre-soldered joints. If you solder too long the flexible PCB melts, so I had to connect one wire at the source, rather than connecting to another strand. These lights are not waterproof (like the decorative tape), so I put some clear shipping tape over the lights, and for now it works. I may find something else that is clear and transparent to put over them in the future, possibly diffusing the light. The results are stunning to say the least. I put the strips on the side of the battery holder, top rear of the front fender, and on the top and back of the rear fender.
(bonus) Bike Ride without batteries. https://youtu.be/lUGYwVO3eQo
#8 See it all in super fast speed: https://youtu.be/eNpMfA9QTro
#9 Installing Motor Start Capacitors Man VS Junk 239 https://youtu.be/5_rbPmZTrv4
#10 Lightcycle Night Ride Outdoors Pomeroy WA https://youtu.be/SHVm-Q1eXRI
Some audio used in my videos comes from http://www.teknoaxe.com with permission to use their content in commercial and non-commercial videos.
#Assembly #Construction #Techniroux #Lithium #20Ah #ExternalBattery #Ebike #Custom #Built #Output #affordable #lowcost #ultralight #lightweight #LongLasting #hack #upgrade #HowTo #Guide #DIY #ElectricBike #Bicycle #Battery #Power #Instructions #Tutorial #Travel #Transportation #Ride #36V #48V #rechargeable #HubMotor #BMS #BatteryProtection #Charger #PCB #Board #Circuit #Wiring #Schematic #Diagram #Conversion #PowerBank #20000mAh #ManVSJunk #Budget #Science #Technology #Energy #Electricity #DC #Watts #Amps #Easy #Simple #Value #easiest #simplest #Best #DoItYourself #Cells #Pack #BMX #Bike #Custom #Build #BatteryManagementSystem #HomeMade #Invention
Battery total weight with case, wiring, & BMS: 7.156 pounds 114.5 ounces.
Just the batteries weigh 6 pounds. IF YOU ATTEMPT THIS PROJECT, IT IS AT YOUR OWN RISK !!! WATCH ALL VIDEOS FIRST, AND DO PROPER TRAINING. This battery is the lightest 36v 20Ah E-Bike battery that I know of. The next lightest one is much more expensive, and just under 9 pounds. NO spot welder needed !!! I just built one of these batteries myself, that weights 7 pounds (with the casing, wires, and electronics), and the total cost would have been $262.55 if I had to buy the batteries, but I got the battery company to send me these batteries for free, and paid only $32.85 for the charger and BMS. I also got some thermal adhesive and an in line fuse (not required). The chart below I made, shows the comparison of weight, price, and battery type.
Although the lightest Lithium Battery above is 13.2 pounds, I found one online that was just under 9 pounds, but it also was about $800.00. This means that my battery is worth more than any other battery I've found on the market, because of it's weight. I could have removed more weight by removing the plastic cases, electronics, buying plastic spacer holders, and using a spot welder (I don't have one) to connect the cells together, but this would have required more time, more work, and more money. The way I did this, anyone could do it, and for under $300.00
The bike: solar tracker SLB-2000 bike
INDEX:
#1 Techniroux Power Bank 20000mAh External Battery Review https://youtu.be/6UYBeWEc49M
#2 The Plan for the Build https://youtu.be/yyia52BQeZk
#3 Techniroux Power Bank Dissection https://youtu.be/viD492SvMoM
#4 DIY Techniroux Lithium E-Bike Battery Assembly https://youtu.be/tMkQVajCFws
#5 Installing the BMS DIY Lithium E-Bike Battery https://youtu.be/IWIM32AKwE8
#6 Bike Ride, E-Bike Test https://youtu.be/pGaQnvXySE0
#7 LED Light Cycle & Decoration https://youtu.be/NHooHXAOToo
(bonus) Bike Ride without batteries. https://youtu.be/lUGYwVO3eQo
#8 See it all in super fast speed: https://youtu.be/eNpMfA9QTro
#9 Installing Motor Start Capacitors Man VS Junk 239 https://youtu.be/5_rbPmZTrv4
#10 Lightcycle Night Ride Outdoors Pomeroy WA https://youtu.be/SHVm-Q1eXRI
#1 Techniroux Power Bank 20000mAh External Battery Review https://youtu.be/6UYBeWEc49M
#2 The Plan for the Build https://youtu.be/yyia52BQeZk
#3 Techniroux Power Bank Dissection https://youtu.be/viD492SvMoM
#4 DIY Techniroux Lithium E-Bike Battery Assembly https://youtu.be/tMkQVajCFws
Parts List:
Techniroux Batteries https://amzn.com/B01LQ6Q3OI (Free)
BMS https://amzn.com/B01CQXERLQ
1.5A Charger https://amzn.com/B01ABGAGTM
Arctic Alumina Thermal Adhesive 5g https://amzn.com/B0009IQ1BU
#raspberrypi Raspberry Pi Starter Accessories Kit https://www.youtube.com/watch?v=Px-P6ZpVna4 (FREE)
3D Pen https://www.youtube.com/watch?v=iyVwSq9KZvw (FREE)
#EL-AW-05/BLK-10 Devek Synthetic Rubber Premium Grade Electrical Insulation All Weather Tape, Black (1/2 in x 66 ft, 12mm x 20m) https://www.youtube.com/watch?v=4Y6Rp-2GJXs (FREE)
Ustellar Led Light Strip Kit Led Strip Lights SMD 2835 16 4ft 5m 300 Leds Non waterproof 12V DC Fexi https://www.youtube.com/watch?v=wdVZpzG-U7w (FREE)
#washitape Decorative Craft Masking Washi Tape Set of 12 Rolls Gold Black White and Silver Japanese https://www.youtube.com/watch?v=TKfPNWDVmF8 (FREE)
Other Items I use:
#BicycleMirror Ohuhu Bike Helmet Mirror Bicycle Mirror Cycling Mirror https://www.youtube.com/watch?v=HDYPc9z84OA
#Leedemore Bike Pump, Aluminum Alloy Mini Portable Bicycle Frame Pump, Compatible with Prest https://www.youtube.com/watch?v=weVKkAehQOQ
#BX550 Night Provision BX-550 USB Bike Light https://www.youtube.com/watch?v=ALhVo410xP8
#UnisexOutdoorTouchCyclingMountainBikeGloves YUEDGE Unisex Outdoor Touch Screen Cycling Mountain Bike https://www.youtube.com/watch?v=x9UByrzAwr8
#BluetoothSpeakerswithBicycleClipandSuctionCupBase Bluetooth Speakers with Bicycle Clip and Suction https://www.youtube.com/watch?v=AtiMV9NFGxE
#Tedgembikeclockblue Philonext Bike Lock Cable 4 Digits Combination Cable Lock with LED Light https://www.youtube.com/watch?v=rwsWYwlF350
#thebrightoutdoors Bright Outdoors LED Safety Light Flashlight Red & White Lights for Running, https://www.youtube.com/watch?v=hQtOzgVZzr8
#balaclavafacemaskwintergames Ski Face Mask Sports Neck Warmer Balaclava Jill Up https://www.youtube.com/watch?v=goX7SUwiw9c
#promotion Fit Over Glasses Sunglasses by Great Pick: Polarized Plastic Glasses to Wear Over Regular https://www.youtube.com/watch?v=NXWN4UFuWOM
My Electric Bike https://www.youtube.com/watch?v=S5XXo61R6No
#5 Installing the BMS DIY Lithium E-Bike Battery https://youtu.be/IWIM32AKwE8
Part A & B Thermal Adhesive holds the Heat-sink on, yes I could
have cleaned the heat-sink first. This BMS (Battery Management System)
only created 1 degree F temp increase from room temperature when
charging. In the summer I don't know what it will do on the road. This
BMS doesn't require a heat-sink, but when people run a BMS without a
heat-sink they usually don't last. This one is rated for 30Amps - 40Amps
peak, and the bike has a 20 Amp fuse, so it should be more than enough.
I have 3 Heat-sinks left, I harvested them for free from computers.
Without a BMS Lithium batteries in more than one pack (10 packs) won't
survive. They also don't survive freezing temperatures, or extremely hot
temperatures, so it's best to keep them inside in the winter when not
in use.
The case, is for a Raspberry Pi 3, and someone
sent it to me for free. I also used a 3D plastic printing pen to mount
the PCB board into the plastic Raspberry Pi 3 case. You can see the blue
plastic on the bottom. I also got the 3D pens for free, and They are
sold for children to do art, but they are great for plastic welding,
making parts, and as you see here mounting PCB boards to plastic. I made
some plastic rivets to go threw the mounting holes on the board. Using
the Light to cure the plastic wasn't easy, because it was very thick,
but the clear plastic case allowed the light to go threw, and cure the
plastic. The plastic doesn't harden and remains a liquid until using a
special UV light that comes with the pens.
I had to print 4 - 5 layers of plastic using the 3D pen, and then I squirted it threw these holes you see here, and hardened it, and then put plastic on top to make rivets as seen above. I also put plastic around the upper corner to make sure it was held in place. So far the plastic seems non-conductive, and everything works well.
#6 Bike Ride, E-Bike Test https://youtu.be/pGaQnvXySE0
During the TEST RUN, I discovered that the Hub Motor on the bike has a speed limit, and shuts off after you get up to 20 MPH, it also won't go unless your already moving at a decent speed. It will start and shut back off if it's not already moving. Thankfully the motor only has two wires. Maybe some day when doing maintenance on the Hub Motor (difficult to take apart) the speed limit can be bypassed. Because the motor is under 750 watts, it doesn't climb hills on it's own and requires peddle assistance, however it does go up shallow hills on it's own. After a 17 minute test ride, the batteries didn't seem discharged.
#7 LED Light Cycle & Decoration https://youtu.be/NHooHXAOToo
At first I tried using a 24-36v step down to 12v 5A converter, but the converter used so many AMPS that my BMS decided it was too hard on the batteries when I turned on the motor at the same time. I didn't blow the 20A fuse ! Apparently the BMS can detect when the cells are too stressed, and shuts down right away, and doesn't come back on for at least 30 seconds. I removed the converter, and hooked up a small 12v Lead Acid battery instead. The lights on the bike draw .5 Amps at 12v, so I should have no problem keeping the lights on. I have some other cool 12v ideas as well. After the BMS shut down and I thought the fuse blew, I decided to decorate the top cover of the battery with the Decorative Craft Masking Washi Tape. This tape is just paper tape, and isn't waterproof, so I used some window shrink plastic, and double stick tape, and then shrunk the plastic with a hair dryer. The results look very impressive, and I can still take the battery apart to work on it. I also re-attached the battery meter / headlight on the bike, and realized that the horn doesn't work, but at least I have a battery meter. I need to replace the 36v bulb, with an LED bulb.
I discovered that the copper connections on the Ustellar Led Light Strips, can not be soldered to with normal solder. I did find some solder joints with solder on them every so many feet. (sometimes in the middle of a strand I cut) so I soldered the wires to these pre-soldered joints. If you solder too long the flexible PCB melts, so I had to connect one wire at the source, rather than connecting to another strand. These lights are not waterproof (like the decorative tape), so I put some clear shipping tape over the lights, and for now it works. I may find something else that is clear and transparent to put over them in the future, possibly diffusing the light. The results are stunning to say the least. I put the strips on the side of the battery holder, top rear of the front fender, and on the top and back of the rear fender.
(bonus) Bike Ride without batteries. https://youtu.be/lUGYwVO3eQo
#9 Installing Motor Start Capacitors Man VS Junk 239 https://youtu.be/5_rbPmZTrv4
#10 Lightcycle Night Ride Outdoors Pomeroy WA https://youtu.be/SHVm-Q1eXRI
If you want to see more #Review, #Repair, #Outdoor, and #Gaming videos, please donate via #Patreon.
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#Assembly #Construction #Techniroux #Lithium #20Ah #ExternalBattery #Ebike #Custom #Built #Output #affordable #lowcost #ultralight #lightweight #LongLasting #hack #upgrade #HowTo #Guide #DIY #ElectricBike #Bicycle #Battery #Power #Instructions #Tutorial #Travel #Transportation #Ride #36V #48V #rechargeable #HubMotor #BMS #BatteryProtection #Charger #PCB #Board #Circuit #Wiring #Schematic #Diagram #Conversion #PowerBank #20000mAh #ManVSJunk #Budget #Science #Technology #Energy #Electricity #DC #Watts #Amps #Easy #Simple #Value #easiest #simplest #Best #DoItYourself #Cells #Pack #BMX #Bike #Custom #Build #BatteryManagementSystem #HomeMade #Invention
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