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Tiny motorcycle battery (how to build an A123 pack)

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Uploaded on Oct 19, 2010

Here's a battery for your motorcycle that weighs in at under 2 lbs! It's only 4 x 2.5 x 2 inches in size. It has approximately 200 cold cranking amps and 4.6Ah capacity.

This battery successfully cranked my 1200 Sportster 6 times in a row with almost no break or significant charge time (6 cycles of engine start followed by less than 10 seconds of run time, then shut down and repeat). The battery pack showed no sign of slowing down.

The down side? It's a bit expensive (expect to spend $150 - $200).

An R/C battery charger is recommended for initial charging. However, it's supposedly safe to use a 5A car charger with close monitoring (they charge fast - under an hour!). Thereafter, the motorcycle's charge system should be adequate. Do not use a trickle charger (Battery Tender) with A123 packs.

Additionally, these batteries are resistant but not impervious to imbalance. I did not include balance leads on my packs, but they may be worth using in order to perfectly charge the pack from time to time.

Here are the parts sources I promised:

26650 A123 cells, 145mm shrink wrap -- battlepack.com
Dewalt DC9280 or DC9360 battery packs are another source of batteries
Forklift connectors (6382PT) -- Amazon (or McMaster 7043K91)
Hyperion battery bars and balance connectors -- aircraft-world.com
6AWG welding cable -- www.mcmaster.com
6AWG ring terminals - Home Depot
MegaPower 930SR 1S~12S Li-po/A123 Charger + LCB12S -- aero-nuts.com

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