How to build a MASSIVE 72V DIY battery pack for high power e-bike
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- Опубліковано 3 чер 2024
- 20s14p Li-ion battery pack
Samsung 30Q cells
72V 42Ah
Max continuous discharge 220A
Max peak discharge 300A (BMS limited)
Dimensions (mm) 325 x 144 x 126
Want me to build a battery pack for you? All details here:
calendly.com/gaiusgarage
Need help designing you battery pack?
calendly.com/gaiusgarage/batt...
eBike using this battery pack
/ ch5lhnsg-xh
Samsung 30Q cells
liionwholesale.com/collection...
18650 holder STL file
www.thingiverse.com/thing:466...
20s ANT BMS
www.aliexpress.com/item/Smart...
ANT BMS iphone app
apps.apple.com/us/app/%E5%8D%...
kWeld spot welder
www.keenlab.de/index.php/port...
Additional drawbacks of kWeld not mentioned in video
/ gdxqd7q
Nickel strip
www.aliexpress.com/item/32883...
Copper plating used in series connections
www.aliexpress.com/item/32840...
400mm heat shrink wrap
www.amazon.com/Battery-Shrink...
Kapton tape
www.amazon.com/s?k=kapton+tap...
18650 Insulator rings
www.amazon.com/Battery-Insula...
EC8 connector
www.amazon.com/Connector-Bull...
#electricmotorcycles #ebike #diy #motorcycles #lithiumionbatteries #diyebike #motorcycles #caferacer #dirtbike #electricvehicle - Навчання та стиль
Best part of this project is the cool OG red shop rag on the workbench. Well done, sir...
Wow! This was an extremely helpful video! Great find! Thanks for making the vid!
AmaZing detail. Answered a lot of my questions about large packs.
So dope. We need more videos from you about your bike, builds, specs, etc....
thanks! going to post alot more of those soon, including new bike build with 100V Lipo pack
Great in-depth video.
Waiting for more.
I'm buying a year old Daymak EM2 today.I want to convert to lithium from lead acid.Videos like this are helpful.Thanx🇨🇦
only 3 minutes in , it's obvious how mucht thought and precausion has gone into the assembly. very nice watch, thanks .
thanks so much!
What a beast!! Nice tidy work
Serious pack build Hands down the best video on the topic. Great method for durable bonding and agree with the copper buss and soldering technique you employ. Hard to get the Samsung 30Q 3000mAh Got to choose from what isn't sold out. And as with everything post pandemic they are more than before. Certainly in Aug 2023 you are looking at ~$900 USD for 84V 20A alone.
I would buy an 84v 23S 10P pack off the shelf but it is a fools game. No BMS and no idea as to brand of 18650. I have to give serious thought to replacing the lead acid batts in my Damak Eagle
I have built a few packs in my time. This is a nice build.
Thank you!
Professional build, good job 👍
Unbelievable work, very helpful video!
That thing is a beautiful monster. I'm sure it could power my whole house for a week.
👍🏻nice build man i miss these kid of video’s. Much appreciated👊🏻
Thanks so much!
I built a vruzend kit battery 54volt.Samsung 25r cells.but got battery sag after a while so bought a green cell battery
Love it! Very talented. 🙏
It's always interesting to see how we bother with wire size but solder can take it all. Same solder can take 10A or 1000A. Beautiful material :)
I love how you're not effing around with any of the connections through soldering and spot welding!
thanks! yeah Im never opening this thing back up to service it - if one of those come loose or dislodge this whole thing will be significantly stifled or completely defunct. just thinking in terms of all the vibration over time and climate effects plus electrolytic corrosion - I really dont think I did a good enough job. but still nice a balanced a year later!
@@GaiusGarage Ya welcome!
Honestly, the only other thing ya could have done is that after soldering, but before folding it up, was conformal coat the internals!
I think this would be perfect to extend the range of my Evo3 a little 👍
Awesome video...I'd just learned a lot of what are needed. Thank you
This was a great build video, pls keep em coming. I am just finishing my first 52v 20ah pack and this helped give me some ideas on finishing up, I'd love to see some of your ebike builds as I have a qs205 5t sitting here waiting to be built into a rim.
Thanks alot, Rich! I'm not the best about recording the builds Ive done and posting them but I'm planning on putting some more stuff up. The bike I have linked in the description is a 4T QS205. Theyre great motors and can handle a ton of power. feel free to reach out if you have any questions once you get building. happy to help out! which controller will you be using?
@@GaiusGarage I have a Nucular 12f I got from Russia and am shooting for 10kw. Looking for suggestions on a frame and still need to choose a rim to lace the motor into if you have any guidance. Cheers.
@@RichardNBBarrett ah nice! Id love to get my hands on one of those - how's the programming? I got this frame from ebay mainly because it was cheap and I though it looked pretty good: www.ebay.com/itm/Electric-Bicycle-Bike-Frame-Kit-Stealth-Bomber-Electric-Bicycle-eBike-Frame/223609867251?hash=item34102fcbf3:g:HHAAAOSwg9hdOWpv - its a little heavier than Id like but ultimately solid and has alot of space for the battery, which as per this video, was a must. The other frame people use is this enduro frame (just search "ebike enduro frame" on aliexpress) but its like $600 and less space - although its probably a bit lighter and more ergonomic. I got 17" motorcycle rims on mine with enduro tires - can find the links if you'd like - kinda depends if you want more speed or acceleration but with a 5T, 17" wheel will give you a lot of kick, meanwhile 29" bike tires would give you max top speed but Im not sure you would get much above 45-50mph with 5T. Im getting 55mph top speed with 4T motor and like 24" outer diameter at the tire. then again field weakening might give you some extra top speed
@@GaiusGarage haven't tried programming it yet but from what Ive seen it looks very clean and well laid out with some auto-tuning options as well
@@GaiusGarage For the 14s10p I am building, its just for a 750w-1000w hub in an eBike I put together last year. I am going to set the controller in that existing bike to 30amps max so quick question 12awg silicone wire should be fine for the terminals for that battery pack right?
With the prices of batteries, debating dipping my toes into trying to build a pack. I need a larger AH battery, the options are just too expensive though. Thank you for showing me the basics.
Brilliant build.
Insane battery!! Looking forward to a video about the ebike!
That was a great video I like the way you put the pack together
thank you!
Wonderful build, I'm planning to build one soon.
thank you! feel free to reach out if you have any question
Literally a bomb!!! cool big pack batts :)
Really enjoyed this, thanks!
Awesome video. Super informative and clear
Thank-you so much for this video. Good job, and very helpful.
Very nicely done. It´s pleasure to watch.
thank you!
Great build
You know its a big ass battery when you need a gas burner to solder, love it!
Gorgeous pack, definitely not your first and if it is then even more impressive, now just to see it in action👍🏽
not my first battery build but my first (and only) one of this size - although I did build another ridiculous pack from Lipo cells that Ive been meaning to post but too lazy to edit lol. thanks alot!
@@GaiusGarageI hear you there, i keep meaning to do the same but couldn't be arsed, have enough to be doing already 😛
nice! I learned a lot about safety!
How did you hook the main negative and positive discharge wires to the pack
Luke tamblyn how do you tape your battery to your frame one so it doesnt move and two how do you make it look so good
love this video. very therapeutic
nice job! Where did you got those Copper plates and what are they used for in real life? Thank you :-)
Excellent build 👍
Amazing work and amazing music as well
thanks so much! this music is from a great playlist I found on youtube a few years ago - lots of other awesome tracks check it out ua-cam.com/video/uL0mvPZuklM/v-deo.html
@@GaiusGarage Thanks you are awesome art maker and listener . Keep up the good work always .
Looks good, but you could have used more cells at the same volume with a different design. How do you support it against mechanical impact?
Hi man, thank you very much for this video! Could you PLEASE share parts list of your awesome stealth bomber ebike? I would like to build something very similar, it would help me out a lot.
Absolutely superb in depth video.So well explained and filmed put. Like many here, I’d love to see this on the bike that its been made for and demonstrated 😊 👍
thanks so much! pic of the bike using this battery pack is in the comments - going to make a ride video soon!
@@GaiusGarage Looks great 👍 There’ll be a few people (including myself) glad to see that video.|I bet that machine really shifts 👍
ditto to the above comment by jonnyswlk4674, i canna say anything more, this is the best instructional video i ever saw, alas i don't understand much of it lol.
@@GaiusGarage Hi hello sir, may I allow to ask a question and please help reply with your expertise on ebike battery. Yesterday when I was paddle my ebike at home with the parking stand mount on the floor, for testing the ebike speed, then suddenly my mother was talking to me, instead of I need to press the hand brake to stop the spining ebike, I turned off the ignition key, THEN I heard a "pop" sound (the motorhub was still in high speed spinning) I don't know the "pop" sound was came from the battery or came from the controller. Sir, may I ask in most of the cases, let say, if a person paddle the ebike halfway through, when the battery still on going supplying the energy into the controller, and the controller still on going supplying the power into the motorhub, and the motorhub still drawing power spinning at fast speed, then he turn off the ignition key OUT OF SUDDEN to cut off the ON GOING power supply intake from the battery, in this case what will happen to my battery? Sir, please help me,
then I unpluged the ebike power plug from the battery, then I turn on the key ignition to purposely release the electric in the controller, then I plug the ebike power plug into the battery and heard a as usual spark sound.
My concern now is, how do I know I already wound, injury, or damage my battery or not sir. Hope you understand my question, trillion thanks if you would please reply sir.
@@GaiusGarage it's ok to charge from the main output connection on these batteries? my EUC battery has two pairs of smaller black and red wires coming out that don't indicate any voltage
Nice job building that pack. Now show us what type of bike that beast is being mounted onto!
Thanks! link to ebike using this pack is in the description
Beautiful job
That's a beast!!
Sandwiching the copper plate with another piece of nickel or steel works well.
Goodness, I will be building a 20s20p and never relized how enormous this would be, i love this design. Would love to see what its for
yeah I was originally going to build 16p but there was no way to arrange the cells to fit in the frame. 20p would be huge! links to pics of the bike in description!
@@GaiusGarage i have not made any purchases in electronics yet however i am thinking of building a 4kW nominal motard
@@GaiusGarage I am going to use this same layup (2x7)x4x5 however I will check wether a (2x10)x4x5 configuration or (3x7)x4x5 would fit the frame best.
That was AWESOME!
thanks so much!
Honestly, I would recommended you use Molicel 45a 21700 4.2ah cells they are the bang for youre buck!
Where did you get the foam sheets?
Hey I wrote a comment yesterday about my 52v battery that I could only get a reading of 14.5 volts out of. You replied saying I could do a zoom but I just thought I would write another comment to tell you what I would consider to be very important information before we go on the zoom. So I opened the battery a couple minutes ago to test the voltage, and I put the negative prong on the negative nickel strip and positive on the positive nickel strip, and I got a reading of 58.2 (52v is 58.8 full charge) so that’s the right voltage. Part of the bms wires are exposed so I put the negative prong on the negative bms wire and the positive prong on the positive wire. It read the exact same voltage of 58.2. Before, my worry was that the positive or negative wire wasn’t soldered on good enough, but now I know that they are and both give the correct voltage. This is good, because now I know 100% that it is an issue with the bms and not something else. I am going to book a zoom call as I would love to hop on a zoom call with you to get this figured out. Especially now that I know the problem. I just thought I would write this comment to let you know what I’ve narrowed it down so that way on the zoom we can get it fixed.
Oh nice! yeah sounds like your pack is in good shape, which is the important part!
@@GaiusGarage What day/time for the zoom works best for you? I have a lot of free time so I just want to make sure to book a time where you have the full time and focus to help me out. Just lmk what works best
@@schmeglyomigy6174you can choose a date/time on my Calendly calendly.com/gaiusgarage
Hi,
Did wraping the battery in hear restant foam cause any heating or overheating or slow cooling issues? I want to wrap the battery i am building in foam as well for decrease vibration but am hesitant about overheating issues.
Great built.
No, I never had any issues with overheating. heat is not really an issue unless you're really pushing a battery pack to it's limits. in this case, I would only run it at max discharge for short periods of time (when accelerating hard) but most of the time the demand was much more moderate. so overheating was not an issue even when wrapped and placed somewhere with little airflow
Love it 👌
great video, clean build! i'd like to add to the importance of using insulator rings, my 12.6v 60aH build after 3 years had about 8 cells "pop" because the nickel somehow punctured into the factory protective film at the top of the cell (positive side), causing the positive to meet the battery shell (ground). First time i've ever smelled li-on fumes and surprisingly smelled like Lychee candy lolll. Ever since then, i've used insulator rings on all my builds, and still paranoid!
I added those here 1:09
@@GaiusGarage yeah, was saying im adding to the importance of it, loved that you put it in the video.
Hi Yev love the info you've shared in your video. I'm attempting to build 22s 9p battery pack, possible to pick your brains about how I'd go about folding such a pack?
for sure! if the dimensions work for you, you can do it exactly the same as in the video but with two 11s groups of 3x3 cells. you should have pack that's 715mm x 54mm x 108mm
Know what ?? I will use a 550 watt soldering iron to solder the copper strips !! Fast job ! My original idea is to melt things to hell with this thing . Also , that you have said for 220 amps , that can easily output about 800amps if needed , or that is what I would let it do . Well if you think where the heck did I get the idea of doing destruction with this beast , have a look at the channel named : COLIN FURZE !!! He is an absolute beast !! This channel too is amazing ! Nice videos ! Keep it up ! Hope you get a sponsored soon !
You are correct, when you put cells in parallel they attempt to charge each other. However, that is not a whole story, because when the batteries begin to discharge, the more charged cells will attempt to charge the less charged cells. This reduces the total output of the battery as you draw power from it. The only method I have found to prevent this, is to put a schottky diode on the output of each cell, then tying the diode cathodes together. Or you could at the end of the series, which will reduce the amount of diodes necessary. It really depends on your battery configuration.
how would this affect the battery during charging
@@Matt-og5kd That's a good question, I don't think it affects TOO much, since this is a configuration found in car batteries. It might slightly increase charging time perhaps?
*Will Smith Voice
YAAHHH. THAT'S HOTT. That's hott.
I'm impressed
How many amps would be this config......??Quick question, I just got a 72v battery pack 20s and believe is 6p, have 120 cells in it (liitokala 5000) but not sure how much amps really is as it doesn't have any labels.
Really nice job and great battery pack, but I belive that you shouldn't trim bms balance wires, it introduces resistance difference in wires and could interfere with the bms readings
thank you! interesting thought on the balance wires - to my understanding the BMS is measuring the voltage potentials only from the balance wires, in which case the current (dependent upon resistance) wouldn't matter. but if the BMS performs some other functions that depends on measuring current in the balance wires with some high degree of precision, then their length might play a role
What charger you use to charge the pack?
I heard solder and high current dont mix well because the solder can potentially heat up enough to liquify under high draw. Any thoughts on this?
Most common solder melts at around 200C - if your connections are heating up this much during use, you've got much bigger problems
awesome thank you
Lovely stuff. I think I have the eBike for this. Do you know what it weighs by any chance?
Thank you for the tutorial. I'm building a pack of a similar size. Are there any safety risks associated with working with voltages above 50V?
yes, any amount of voltage is dangerous and becomes more dangerous as the voltage increases. always use gloves and take precaution when working with high voltage
I'm sure you heard about the sur ron X ! Did you think this battery can fit in the battery caps of the sur ron and it's possible to work with sur ron motor and bac 4000 Controlor ?
it would work with sur ron motor and bac4000 but there's no way this will fit in the battery compartment. maybe if it were arranged differently
Well Done - Thanks
i watched this video 100 time love it and started printing those cell holders will build same pack for 8000w 200a ebike
sick! thanks so much. glad this video is helpful for people! please reach out if you have any question at any point. happy to answer!
How long copper plate you used for this project ?
@@shavkat84 I didnt measure it - just whatever length is needed to cover the p-group
Great video! Would you be willing to put a link in to the copper you used? I have searched everywhere. I have found some thats close but not the same and will require more soldering then i want to subject the cells to. Any help here would be great. Thanks.
thanks! please see the link in the video description
Mm my electric scooter dont use more than 21 A drawn so we dont need that much amp drawn but am I correct?
Do you know where I can find this copper strip for series connection for 21700 cells?
not specifically, but Im sure you can find something on aliexpress
Thanks for the video. I have a question about my electric Weped GT50 scooter. It has a stock 60V 1800W dual motors that can handle continuous 30A each but my battery is only pushing out 14.7A max and 9.8A continuous. Do you recommend a battery with 60A continuously for 2pcs 30A motor, peak 120A? The existing battery pack including the BMS is 14.4L x 5.4W x 3.4D inches.
you'll definitely get more power & acceleration with more current but your battery is not necessary the limiting factor. ultimately, the controller determines how much current is being provided to the motor(s). It's possible that the battery isnt able to provide enough power to the controller but if everything is stock, chances are it's all designed to be complementary. Its also possible that your battery pack is capable of more power but the current is limited by the BMS. Basically, it barely matters what the rating is on the motors - most can operate in a wide power range range - how much power they actually receive can be limited by the controller, BMS, or the battery pack itself. more power means upgrade one or all of those components
@@GaiusGarage Oh wow thank you for the feedback. as long as I don't need to upgrade the motors I'm sure I'll be happy to swap out the BMS / controller / battery.
@@cainetastic Looking at building a eMotocross bike. For higher amperages look towards golf cart setups.
Excellent work. Very nice build.
I cant find the 220 continuos 300A max discharge BMS.
The ones available are 240A continuous but 550A max.
Im usisng 14P sony VTC6 cells so I have max 420A discharge.
Should I go for a lower continuos discharge? Let's say 170 continuous 425A..
Thank you.
you should size your BMS to the peak discharge of what your system will be running
@@GaiusGarage thank you
I need that one.
Hi mate great video I am looking to build the 20s battry but with only 6p I got 120 Samsung 40t, 21700 cells my controller is sabvoton 100a and I think 6p is good enough for my need now I need help with battry configuration is there any advice or software by the way my frame is stealth Bomber same as yours
I am doing the same in a stealth bomber. I have 200 iam trying to do 20s10p. I am waiting on the battery cells to arrive this week. I feel like this 4 module rectangle should fit. With less sells it should fit easy and with a big control inside.
How can this battery be utilized as to what i/o needs to be connected to get a 3 prong 110v outlet to power on a microwave, phone, smartphones, tablets, and a solar panel for charging this battery pack...etc... mainly I'm thinkin off grid R.V.
you wouldn't use a battery pack like this for off-grid because the voltage is too high and it was designed for high current draw, which you typically wouldn't need for off-grid. you'll have trouble finding components and will have alot of losses in efficiency. generally off-grid systems use 12V, 24V, or 48V battery systems. youll need an inverter to get AC power from a DC battery like this
Brilliant stuff, I'd have watched this if it was normal speed the whole build. If possible, could you release an unedited build showing every moment, like you did here but without speeding up or doing cuts. Either way this was the best battery video for powerful ebikes I've found from months of looking
thank you! I actually don't have the raw footage anymore but even if I did it would be hours of footage. is there anything you wanted to see more closely in particular?
@@GaiusGarage oh belive me I know it would be hours haha and it was more interest toward the techniques used throughout the process, this video covers everything in wonderful detail, I was just thinking if you're doing the battery build anyways filming the workspace even without talking much would show the nuance detail. Again this video is easily great enough for using as a building manual. I just really enjoyed this build and if a future one is ridiculously long I would just watch it in sittings a few times over before going about building my own powerful battery. Just something to throw out there if you were looking for any ideas. All the best mate 👍
@@GaiusGarage hello big brother im live in turkey can you gift me another litle battery please?
@@memcan5602 😂
@@Anees- our money is worthless
Thank you for the video damn that thing is massive lol
Great video. Can i ask what the reason is to fold over each pack of 14 cells?
Thanks! just to achieve that particular form factor
How would one go about and charge this pack?
Hello nice vid are you going to post more about your e bike,?
Thats awesome
Hi! Please tell me, are there any temperature sensors installed inside the battery module of the electric motorcycle Zero S? I was repacking the battery on my Zero S and I would like to know if the BMS board will work correctly if I don't install sensors?
Im not sure about the battery on a Zero - if I had to guess I would say it does have a temp senor
Very nice build
Thank you, sir!
Great video. Got my sub. I'm trying to buy the kweld. How did you go about purchasing one? I'm planning to do a 72v battery for my ebike. Waiting on my controller from ERT. Thanks 👍👍
please see description - link to Kweld is there. thanks!
sir may i know the charger you are using with this huge capacity battery? and can you please share the link too... thank you very much
What battery would you recommend to make a monster e bike battery 120v or something more trying to get a sir ron over 22kw
If youre using Li-ion cells, you would need about 28 cells in series to achieve 120V at full charge - you'll need to figure out what cell type fit your space requirements but then also meet your current discharge needs
Thank you
Can I get your contact number please
thank you for this video. I want to do with 20p 20s 72v . i' ve got a 400A bms is it ok? what you think?
20s20p will be huge! depends on current rating of each cell - suppose its Sony VTC (20A discharge) 400A will be ok for continuous discharge but if youre using higher discharge cells like Molicell (35A discharge) BMS will be the limiting factor
It's been about 3 years since you posted the video, does that bms still work or have you changed it?
I don't have this pack anymore but I assume the BMS still works. it's not typical for the BMS to fail. Its more likely the pack will go out of balance
Good job
Hi. If I use 4 12 awg copper wire for the positive main discharge would that be able to do the 200 amps continues ? Thanks
four 12awg wires have the about same cross sectional area as one 6awg wire - so yeah should be ok
@@GaiusGarage okay thanks
Wowww awesome 👍👍👍
What is the thin third wire used for? How do you charge the battery?
that wire is the on switch for the BMS to "wake it up". its kinda pointless because you can use it to turn the BMS off and the BMS turns on automatically when you draw power from the battery. Im charging using a 1500W AC-DC power supply and a step-up converter as a voltage regulator
Hey man, can you make a video of your bike, I'm curious how it drives and looks
I actually have a bunch of footage of the bike & riding but been too lazy to edit & post it. planning to soon!
Hi does 20s6p Samsung 40t (rated 30a countinuse discharge) good enough to build the battry with 100amp Continous as I have sabvoton 100a controller and I have exact same 300a ant Bluetooth bms
according to the datasheet Samsung 40T is capable of 30A discharge - 6 in parallel will give you 180A continuous so you should be good
How do you charge them?
Isnt headway 17ah a good option for ebikes?