Battery holder for Dewalt DC9360 eBike

[mastergx1]

tidy, thats about a grands worth of batteries tho isnt it?

[douhnutz]

Have you tried lithium polymer? you can get a 11.1vlt 5000mah for like 30 bucks.

[upcycle]

what is the amp hours per battery? How long to charge a fully discharged pack? What is the low end voltage cut off and/or does it have a cut off voltage?

[RRED2]

What excellent idea, very neat. : )

[kaleeo5]

where can i learn to make the pannel the battery connects too or buy them?

[sponkacom]

very nice;) 5*****

[skowlitz]

i like the lil wooden holder. to have 2 rows of 3 on the sides of your down tube wouldx lower you center o gravity. its a way cleaner set up than hackin packs an taping cells together for sure, when your paying for the name dewalt, then might as well use the paks to your advantage

[alpha3140]

i love the dewalt set up very cool. could i somehow get the electronic blue print on the battery charger /electroncs speed controllrer/ and the way all the batteries sit in and are connected?. do they all (batteries) dump power at once on one rail or is it plug one in at a time or is it a switch? would be cool if you wired a charger on board with a selector for each battery. good luck nice job

[andreschapero]

Please post more videos !!!!!

[arosstor]

Are the Nano battery holders/connectors locally available?

I'm going to use 6 x28v Dewalt Nanos on a chained gear 500w 24v kit.

I'm glad I don't have to take the cases apart.

[anndan85]

Ahhh OK this makes sense! I was like what the heck?

[chicagoelectricbicyc]

No it was a lifepo4. sorry i got the dewalt and lifepo confused.

[anndan85]

and it went 15 miles?

[chicagoelectricbicyc]

The new electric bike I put together I used one Dewalt 36 volt batttery on a small folding bicycle. When I tested it out it was on a outdoor flat surfaced track. It worked fine.

[anndan85]

So you are saying that 1 Dewalt DC9360 2.3 amp hour battery will drive your bike 15 miles and it has a Wilderness Energy hub motor? I am dumbfounded. Unless you are going down a steep hill for the whole 15 miles!

I wish you would start posting at endless-shpere forums about this as I am sure it will stir up quite a contraversy. In my way of thinking and by doing the math, this should be impossible.

[chicagoelectricbicyc]

max speed so far was 29mph. I have not tried to run a series or parrallel config yet. One battery at a time works fine for me. I usually bring a spare dewalt battery when riding. I just swap them out when the battery gets low.

[chicagoelectricbicyc]

On my other electric bicycle I am using a wilderness energy 600 watt 20 inch front hub motor. It runs on 36 volts.

I simply swapped the 24 lb lead acid battery with the 2.5lb dewalt battery. runs great and soo much lighter to carry. I got the idea from your video.

[chicagoelectricbicyc]

Just one dewalt 36 volt battery can last me 15 miles on a charge without pedaling. Why do you need to ride with 6?

[anndan85]

Oh? What kind of motor are you using and how fast are you riding? Inquiring minds want to know!!

[stippidy]

How did you connect the DeWalt to your bike?

[hydramn]

so how long do u charge batteries, do u use same dewalt charger? what range n speed do you like to travel on bike? do you do balancing cells?

[anndan85]

With this seup, I used the Dewalt chargers. It only tkes 1 hour as I had 4 chargers and 2extra batteries. THe chargers do a bit of balancing, but not well. I can get 20 miles if I pedal a bit on 6 batteries.

[anndan85]

With this seup, I used the Dewalt chargers. It only tkes 1 hour as I had 4 chargers and 2extra batteries. THe chargers do a bit of balancing, but not well. I can get 20 miles if I pedal a bit on 6 batteries.

[ktrough]

Do you have any links or tips on making the battery holders? Your design is very clean and I want to do something similar. I am especially interested in how you did the electrical connections to maximize power transfer. Thx! Great work!

[anndan85]

Yes go to endless-sphere forums and look in the sub forum ebike photos and videos.

[kaze0010]

The photos and design info is in a thread called 'All Answer about the Dewalt 36V battery and B M S ---', endless-sphere /forums /viewtopic.php ?f=14&t=2339&st=0&sk=t&sd=a&st­art=30

The materials: plywood (1/8" ?), polyetheylene slab cut to make a battery connector, straps, fuses, case. Nothing scavenged from DeWalt flashlights.

[ktrough]

By my calculations, your overall pack spec is 72V with 6.9Ah of capacity, yes? When you say a 20 mile range without pedal assist, at what speed? I know anything above about 18mph, the losses due to wind resistance really sap the range a lot.

I am going to build a pack out of these for a 36V TidalForce. I won't have the power that you do with the 72V Crystalyte, but it does alright. I will be running the same number of DeWalt packs, but at 36V, so my pack will have 13.8Ah of capacity.

[anndan85]

I like to stay under 20MPH you are correct that going fast cuts the range drastically. I can hit 32 MPH though.

[analyzingfunny]

Nice.

[tubeyoufloyd]

very neat clean setup,could you post information on your hub motor and type of controller please

[sparkypdx]

anndan85 Great looking bike. Where did you get and/or how did you make the battery holder. I would like to keep the dewalt batteries in the OEM condition. Jon J

[anndan85]

Thanks. I made the box myself. I kind of copied some others ideas and put together mine. I got some plastic and had it machined to create a slide for the batteries and used stakes to fit up into the batteries that are held in the plasic. The box was simple to make.

[tsport100]

Why so many M1 cells on a push bike? That's 10Kw continuous, 20kw peak. You could run a car on that!

[anndan85]

No you could not. I think your math is off a little bit. With 6 cells wired in series parallel, I can go about 20 miles without pedalling. In total, I have about 400 watt hours with this pack. 66 volts x 2 amp hours x 3.

[tsport100]

Each M1 cell (you have 60) will discharge at 70A continuous and 120A peak, that's 13.8 kW Cont and 23.7 kW Peak, it just wouldn't last an hour doing it LOL.

You say 0.4 kW/h only gets you 20 miles? No regen?

[anndan85]

No, it would not last long at all with those current rates as the energy capacity of each cell is small. Neither would the little hub motor they drive. ;-) Right I have no regen. The bike is so light, that regen is impractical, at least this is the consensus of what people say that I read about on forums, like endless-sphere. Also, you have to be going at a speed greater than the freewheel speed of the hub motor.

[tsport100]

I have read abit on that forum about the a123s.

Presumably you weigh more than the bike so it's the combined weight that creates the inertial load to run the motor in regen and how hilly/flat your riding area/route is.

Using Regen as an active main brake (as opposed to just passive regen) with one of those reverse twist throttles has to be the ultimate and could add 50%+ to your range.

[anndan85]

There are people on the forum trying at the moment to use a regen function as a brake. This seems to work well. Especially in wet weather.

[pzycho15]

using regens can also convert some foot power to electric energy..depending on the motor, regen could be done easily and brushless motors will have this inherently when slowing them down..

although sometimes (when not using regens as brakes) just learning when to coast can already give additional range..

[jakun2002]

Hi, could you tell me what kind of regulator you hav and how to run this expensive batteries save? Thanks

[anndan85]

I use a Crystalyte 72 volt controller.