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Friday, December 28, 2012

Battery Case Design and Construction



As mentioned in my previous post, the battery case consists primarily of a coroplast housing.  Materials used to construct the battery case are listed below:


  1. white coroplast
  2. UV stabilized cable ties
  3. 4" long bolts
  4. nylock nuts
  5. washers
  6. 3 1/2" long nails
  7. old rubber bicycle tube

The following video highlights the major design elements of the coroplast battery case design:


The following pictures show the battery case from various angles.  I still plan to add an upper and lower fairing to hide the cable ties and wiring that will be running from the handle bars to the controller mounted on the rear rack.
Front 1

Rear 1

Front 2

Right 1

Right 2

Top 1

Top 2


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