How to: (or how I) build a lightweight battery

[benny]

This thread is not yet finished, I'm going to write it as I go a long.

This space will have weight comparison of the final battery with the lightweight one Rick O sells and the standard Yuasa.

What you will need:
- De Walt 36V LI-ON battery (make sure it is brand new, mine was £80 on eBay, that's £8 a cell or £64 a battery)
- 12 AWG wire (black and red, couple of quid on eBay, make sure it's a genuine one and un used)
- gold battery bar connectors (again eBay or local RC shop, can use more 12 gauge wire instead (I may use yellow))
- 22 AWG wire (one length in black and 4 other assorted colours (I use green, pink, blue, yellow) again, eBay)
- battery balancer connector (needs to be for a 4S battery, again just a couple of quid on eBay)
- deans t plug connector (you may need a different plug depending on charger)
- tape (I use blue duct tape, you are probably better with some insulating tape)
- superglue
- solder

Tools:
- a soldering iron of at least 50 watts, preferably 70 watt
- multimeter
- specialist crimper or snipe nose pliers
- soft faced vice (none conductive) or a metal vice with two planks of wood
- scissors, pliers etc.
- Steel rule of some sort
- drill bit and drill
- small torx bits

For charging the final battery I recommend an iMax B6 LiPro balance charger but any charger than can charge a LiFe battery and balance up to 4 cells (4S) will be fine. You could just charge from a normal 4A battery charger but it will reduce the long time life of the battery, reduce the short time (ie capacity) of the battery and must be supervised as it increased risks fire damage. So overall you're best getting something like the iMax (less than £30 genuine if you shop around)

So I've got all the bits on the way and I'll update this thread when they arrive and I start work.

[benny]

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[benny]

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[FiveZigen]

Hi,

Why not just order a premade battery for significantly less? ($44.00 USD)

http://hobbyking.com/hobbyking/store/__ ... _Pack.html

Can even order a B6 charger (clone) for $16 at the same time to save on shipping.

Will you disconect your charging circuit on the bike so it doesnt damage the life battery?

I used a 3 cell lipo in a pinch on my NSR knowing the stock charging circutry on my bike would damage it...I wasnt wrong

Ryan

[benny]

Hi,

Why not just order a premade battery for significantly less? ($44.00 USD)

http://hobbyking.com/hobbyking/store/__ ... _Pack.html

Can even order a B6 charger (clone) for $16 at the same time to save on shipping.

Will you disconect your charging circuit on the bike so it doesnt damage the life battery?

I used a 3 cell lipo in a pinch on my NSR knowing the stock charging circutry on my bike would damage it...I wasnt wrong

Ryan

I've looked in hobby king already. They're all 4S1P I want 4S2P so I'd need ether two of them or find another seller. I'm running total loss so charging system isn't a problem.
I bought my original B6 charger from bobby king UK

[benny]

Hi,

Why not just order a premade battery for significantly less? ($44.00 USD)

http://hobbyking.com/hobbyking/store/__ ... _Pack.html

Can even order a B6 charger (clone) for $16 at the same time to save on shipping.

Will you disconect your charging circuit on the bike so it doesnt damage the life battery?

I used a 3 cell lipo in a pinch on my NSR knowing the stock charging circutry on my bike would damage it...I wasnt wrong

Ryan

Hang on...
This one might be ok.
http://hobbyking.com/hobbyking/store/__ ... _Pack.html
I just realized i purchased the wrong de walt anyway so that's going back!

[willandrip]

What you will need:
- De Walt 36V LI-ON battery (make sure it is brand new, mine was £80 on eBay, that's £8 a cell or £64 a battery)
- 12 AWG wire (black and red, couple of quid on eBay, make sure it's a genuine one and un used)
- gold battery bar connectors (again eBay or local RC shop, can use more 12 gauge wire instead (I may use yellow))
- 22 AWG wire (one length in black and 4 other assorted colours (I use green, pink, blue, yellow) again, eBay)
- battery balancer connector (needs to be for a 4S battery, again just a couple of quid on eBay)
- deans t plug connector (you may need a different plug depending on charger)
- tape (I use blue duct tape, you are probably better with some insulating tape)
- superglue
- solder

Tools:
- a soldering iron of at least 50 watts, preferably 70 watt
- multimeter
- specialist crimper or snipe nose pliers
- soft faced vice (none conductive) or a metal vice with two planks of wood
- scissors, pliers etc.
- Steel rule of some sort
- drill bit and drill
- small torx bits

You forgot the fire extinguisher.

[Neosophist]

http://www.gfracinguk.com/battery-super ... 31npp19mt2

whats the advantage of this when you can use somethign like the above that just drops in and can be charged from a normal bike charging circuit or a standalone charger.

[benny]

http://www.gfracinguk.com/battery-super ... 31npp19mt2

whats the advantage of this when you can use somethign like the above that just drops in and can be charged from a normal bike charging circuit or a standalone charger.

That's what I've got at the moment. I'm relocating the battery from under the seat and the OEM shaped battery is too bulky to go anywhere else.

In the end I've gone for this:
http://www.hobbyking.co.uk/hobbyking/st ... ouse_.html

[MARSHnc30]

Hi Benny just wondering how you got on fitting the light weight zippy battery as I am running total loss system and want a light battery too. Thanks mate

Dan