More on the battery issue

Some delays, and never expected either.

First, my garage is getting too full. Part of the problem is lack of space, part is procrastination on my part. I'm working on it slowly. To help, I've acquired a new tool chest. I'm also finally getting rid of stuff.

The bigger delay, however, is finding an alternate battery to use. There is a limit to the specifications that will work with this powerful motor. It has to be either 48 or 52 volt. And it has to push out enough wattage and amps – and fit within some basic triangular dimensions. So far, only a handful of options are available. The one I selected was a builder of custom batteries. The person is located a few hours from me (2 hour drive each way). He had advertised the perfect specifications. I spent a lot of time getting the dimensions. Because this is a custom built battery, the case is not rigid, it's fit into a water resistant triangular bag designed to fit into the triangular space of the frame. The fit is made a bit more difficult because two of the cables run on the outside (under) of the top post and are not sheathed. They are exposed cables ... anything obstructing their free movement would cause problems.

The dimensions of the battery he gave me was a tight fit, but workable. The triangular bag is a bit on the large side, but it is soft-sided and can be collapsed where needed to fit. And the bag was just slightly larger in one of the dimensions - not big deal I thought.

I carefully measured my bike several times and allowed extra space for the bare cables under the top post. Precision is important here, especially since there is a lot of unusable space where the posts meet and are welded.

After a 2 hour drive, I hit a major disappointment and was unable to acquire the battery this custom builder was selling. I need to point out that I did not feel entirely comfortable with this custom builder, and I am not sure why. I just had a sense that something was off.

The dimensions he provided were not accurate. The height was off by 1/2 inch – and put the height of the battery directly in the path of the bare cables under the top post. The triangular bag he was including for the battery was not right – absolutely not right. It was an Ibera bike bag. The manufacturer's own dimensions places the "width" or depth of the bag at 2.4 inches. The batteries are 650mm or 2.55 inches. With the "welding", wrappings, and internal cables that puts that dimension at 3 inches. So, this builder expects his custom battery, which he spec'd out at 3 inches deep, to fit into a space of 2.4 inches deep. It is a soft bag, but pushing it out doesn't make much sense since that would abraid the sides of the custom battery wrappings, then the wires.

That depth issue set aside, I did not feel comfortable proceeding with the purchase. It does bring into question the skill and expertise of a custom battery builder when they can't get the dimensions of the battery right. Force fitting that battery into a bag that isn't designed for the minimal dimensions is just a dumb idea.

I want to get this project done ... but ... would you have proceeded with the purchase?

Not me, now I am back to looking at the original battery I purchased and considering mounting it to a rear rack until a better solution comes up. What say you?