flamingbicycles

Battery pack assembled and mounted. I test rode it on 18 mile commute and it worked well. One problem, when the battery is first switched on the controller seems have enough capacitor inrush that it triggers the BMS’ short protection. Work around is flipping the switch a few times to fill the capacitors before the BMS stays on. Wiring a bypass of the BMS with a resistor to precharge capacitors seems like a solution. This is new to me so I’m trying to figure it out and am open to suggestions.

Wrapped the battery pack in heat shrink and finished wiring it to the case. I might have to extend some wires in order to get the case closed but everything seems like it is working.

Received BMS with switch wires. Attached all the lead wires to the groups. Need to sort out wiring into the case. Probably should have run the polarity the other direction and attached the BMS to the side with the switch and charge port. Not sure how everything will fit in the case but confident it will work out.

Completed welding on nickel strips. Realized the BMS I had set aside for this pack doesn’t include switch circuitry so it wouldn’t be ideal for the case. Ordered appropriate BMS from aliexpress. I could cover the terminal edges with fish paper while waiting for delivery.

Cut some nickel strips and spot welded them on the pack. Got about two thirds completed before running out of time.

Cleaned up the terminals and put insulation rings on the cells selected for the next battery pack. This is for the Jasion brand ebike that I received in disrepair and tested the motor. I managed to salvage the down tube battery case so I arranged the cells in the holders from that. Nickel strips and spot welding are next. #diy #ebike #repair

Added sides to the homemade cargo trailer. Securing stuff with ratchet straps is a pain and things shifting around to rub on a wheel was getting bothersome.

Sides are framed with 1x2 lumber, screened with hardware cloth and attached with 2 carriage bolts with wing nuts. Should be easy to remove and stack for storage.

#diy #carryshitolympics #BikeTooter

Finished tearing down all the packs I know have Samsung 25R cells inside. Also finished capacity testing the 211 cells that were salvaged. Next step is checking the internal resistance and voltage after they have sat for some time. Then input capacity and IR data into the pack builder tool on cell saviors website and hopefully build some working ebike battery packs. #solarpunk

One of the 14 Samsung 18650 25R cells had no voltage. The remaining capacity tested between 2000mah and 2200mah. Going to let them rest for couple weeks to check for self-discharge. Time to tear down the next battery pack. #diy #solarpunk #electronics

Harvesting lithium cells from salvaged power tool battery packs. The goal is to assemble an ebike battery pack once I get enough cells tested. Have a decent collection of packs from the same manufacturer so hopefully the cells match up for a well balanced pack. #diy #solarpunk #electronics