Frame Bags for Battery and Wire Management.

Gionnirocket

Well-Known Member
Region
USA
City
Y. O.
I don't think I've stumbled on anything novel here.... but I haven't seen anything posted taking this approach.
Recently I purchased a smaller battery that would fit in my very tight triangle and I needed a way to secure it and make it somewhat presentable. That along with following some of @PedalUma's very clean builds I was inspired... or should I say embarrassed into cleaning things up a bit.
So I purchased a frame bag slightly larger than the new 48v/10ah battery and installed it on the bottle mounts by fabricating a 2" W x 11"L x1/8" T piece of aluminum flat bar which attached with 2 fluted 5mm flat head screws that were countersunk to be flush with the top of the bar. The bar was wrapped in padding, slid it in the bag and bolted down. I put some additional padding over the screw heads, at the bottom of the bag and under the bag between it and the frame for good measure. I had cut grommets into the bag by heating up a gasket cutter die and letting it melt though so I'd have a means to pass wires. I did the same to my existing top frame bag that generally held my phone, wallet and keys and used it now to also hold 2 fuse holders, a diode and switch splice for my horn and light and all the bikes connectors.. throttle, brake and display. This still leaving plenty of room for my usual.
I like that the battery bag has a shallow compartment on the left side which I can tuck the charge connector in and that I can easily access my display connector for programming. I now even have a place to store or connect the programming cable for use with the new app and OTG dongle.

Not state of the art by any means.... but I like it 🙃
 

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6zfshdb

Well-Known Member
Region
USA
City
Northeast Pennsylvania
Nice build! Looks "professional" enough to me.

I may do something similar to house my power tool backup battery.
 

Gionnirocket

Well-Known Member
Region
USA
City
Y. O.
Nice build! Looks "professional" enough to me.

I may do something similar to house my power tool backup battery.
Thanks.
Not some of my best work... But as I get older and as my eyesight fails, things don't need to be as pretty 🙃
Probably should have gone for a new top rail bag for this project as my existing one is a few years old and pretty tattered. The cheap battery Rockbros bags is built rather well and is water resistant so it should provide enough protection for the battery.
That's right... I remember your tool battery posts... How'd it work out?
 

PedalUma

Well-Known Member
Region
USA
I love it!!! Thanks @Gionnirocket! Very nice.
Here is that HD cargo build where I tucked the connectors into a phone sack.
Zoom to see the painted zip ties and the HD motor.
 

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Gionnirocket

Well-Known Member
Region
USA
City
Y. O.
I love it!!! Thanks @Gionnirocket! Very nice.
Here is that HD cargo build where I tucked the connectors into a phone sack.
Zoom to see the painted zip ties and the HD motor.
Now I know what to get you for Christmas!
IMG_20210712_173211_557.JPG

 

PedalUma

Well-Known Member
Region
USA
Those look good. I might just do a rainbow bike using this bell. Thank you for the link.
1626126888938.png

What products do you recommend to keep your sack clean? And how often?
 

Gionnirocket

Well-Known Member
Region
USA
City
Y. O.
Those look good. I might just do a rainbow bike using this bell. Thank you for the link.
View attachment 93091
What products do you recommend to keep your sack clean? And how often?
My sack?
I sure hope you mean the frame bag 🤣
I try not to clean anything on my bike with anything more than water as you wash away lubricant from seals and surfaces. The bags waterproofing would also be deteriorated. At most I use diluted Simple Green and a toothbrush on anything stubborn.
 

6zfshdb

Well-Known Member
Region
USA
City
Northeast Pennsylvania
Those look good. I might just do a rainbow bike using this bell. Thank you for the link.
View attachment 93091
What products do you recommend to keep your sack clean? And how often?
When thoroughly dry, compressed air and a stiff bristle brush takes most of the grime off my rack bags & panniers.
 

PedalUma

Well-Known Member
Region
USA
The guy with the red GT said he wanted a rear hub so I did it. I put the controller and the extra wires and connectors into one of those phone sacks. He can wash it after his chamois 🤣 because it is right where muck would fly from the front wheel.
He took it to Tahoe and had me make it into a mid-drive the next week.
 

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Gionnirocket

Well-Known Member
Region
USA
City
Y. O.
Nice job! What battery did you get?

Thanks.


I've only had the battery for about 2 weeks so I wouldn't recommend it just yet as it is very low cost and by an off brand. But at this price point I figured it was at least good for test to see if the weight and center of gravity change is worth spending on a custom build with better known cells. My old battery was a 17.5ah on my rear rack with Samsung cells.
That said so far its been a win-win with the change in the bikes balance being appreciated and the battery power output has been more than adequate. It's only 3p compared to 5p so there is a bit more voltage sag under load, but not enough to affect performance for the way I ride.
For comparison under 8a load my old battery would drop 1v -1.5v and this one drops 1.5v - 2v. On a typical 18.5 mi ride I'd use about 2.5v on my old battery and this one drops 4v. In all its not doing bad at all and on par for its size.
If you Google the manufacturer or check their main page on Ali... They seem to be established in China.
But again, it's only 2 weeks old and could crap out at any moment 🤣 ... But if I get the summer out of it I'd be content.
 

PedalUma

Well-Known Member
Region
USA
The through frame wiring is sweet! Zoom photo #4 in the opening of this thread.
When I have tried to just push it the wiring jams.
Did you pull it? I have used an old shifter cable to do this with heat shrink tube to temporarily join at the connector and nob on the end of the cable. The cable feeds in nicely. Then just pull it along. Far better than a jam.
1626220637776.png
 

Gionnirocket

Well-Known Member
Region
USA
City
Y. O.
I used an electrician fish tape to get from hole to hole and pulled some nylon twine through, then used the twine to pull the wires.
To get the grommets and wire to play nice and sit where I wanted, I coax'd them with a little silicone lubricant.
 

Dallant

Well-Known Member
Region
USA
I don't think I've stumbled on anything novel here.... but I haven't seen anything posted taking this approach.
Recently I purchased a smaller battery that would fit in my very tight triangle and I needed a way to secure it and make it somewhat presentable. That along with following some of @PedalUma's very clean builds I was inspired... or should I say embarrassed into cleaning things up a bit.
So I purchased a frame bag slightly larger than the new 48v/10ah battery and installed it on the bottle mounts by fabricating a 2" W x 11"L x1/8" T piece of aluminum flat bar which attached with 2 fluted 5mm flat head screws that were countersunk to be flush with the top of the bar. The bar was wrapped in padding, slid it in the bag and bolted down. I put some additional padding over the screw heads, at the bottom of the bag and under the bag between it and the frame for good measure. I had cut grommets into the bag by heating up a gasket cutter die and letting it melt though so I'd have a means to pass wires. I did the same to my existing top frame bag that generally held my phone, wallet and keys and used it now to also hold 2 fuse holders, a diode and switch splice for my horn and light and all the bikes connectors.. throttle, brake and display. This still leaving plenty of room for my usual.
I like that the battery bag has a shallow compartment on the left side which I can tuck the charge connector in and that I can easily access my display connector for programming. I now even have a place to store or connect the programming cable for use with the new app and OTG dongle.

Not state of the art by any means.... but I like it 🙃
Love seeing the innovation.😎
 

Dallant

Well-Known Member
Region
USA
Thanks.
A few times a week I cross paths with a rider that I would swear is you. I saw him today and came real close to yelling out Dallant! just to see if he'd turn around. 🙃
Guess I have a pretty common face. Im either riding an Allant+7 or a Rail 5. And I’m mostly in the Great Midwest.
 

Jon A

Member
Region
USA

I've only had the battery for about 2 weeks so I wouldn't recommend it just yet as it is very low cost and by an off brand. But at this price point I figured it was at least good for test to see if the weight and center of gravity change is worth spending on a custom build with better known cells.
Thanks, I have been looking at those for a possible second battery in a dual system. Thinking much the same as you--with their price, you aren't losing much if they go bad. Once you get a mounting system figured out, you can buy a couple of them and if one goes bad just swap in a new one.
 

Timpo

Well-Known Member
Thanks.


I've only had the battery for about 2 weeks so I wouldn't recommend it just yet as it is very low cost and by an off brand. But at this price point I figured it was at least good for test to see if the weight and center of gravity change is worth spending on a custom build with better known cells. My old battery was a 17.5ah on my rear rack with Samsung cells.
That said so far its been a win-win with the change in the bikes balance being appreciated and the battery power output has been more than adequate. It's only 3p compared to 5p so there is a bit more voltage sag under load, but not enough to affect performance for the way I ride.
For comparison under 8a load my old battery would drop 1v -1.5v and this one drops 1.5v - 2v. On a typical 18.5 mi ride I'd use about 2.5v on my old battery and this one drops 4v. In all its not doing bad at all and on par for its size.
If you Google the manufacturer or check their main page on Ali... They seem to be established in China.
But again, it's only 2 weeks old and could crap out at any moment 🤣 ... But if I get the summer out of it I'd be content.
Actually, as far as I know, LiitoKala batteries are okay.
I watch EbikeSchool.com YouTube channel and it does show up every once in a while.

Just get the real one.