December 23, 2022
Description
I made this to fit my 48V 500W BH EasyMotion Evo Cross. This is not a complete battery rebuild how-to, only a bare bones mount that you can modify for your own project. It will probably fit any BH ebike that has a straight battery, with perhaps some modifications. You need to take the connector out of an old battery and screw it on to this mount. BH has proprietary connectors, and I think they're unique to each model, so the posts and screw-holes that I made for my connector might not work for yours. Take a look before printing! Its also a good idea to clip the old cables that went from the battery BMS to the connector and reuse them. On some BH batteries there is a removable fuse on the red wire. I recommend you take that wire with the fuse holder and reuse it in this project.
Aside from the printed parts, you will need:
The “top” and “bottom” pieces are exact replicas of the ends of the original battery (without the cover), and they are held together by an aluminum bar. This is to increase the overall strength and save us from having to print ASA for 12+ hours. You need to drill four holes in the bar: 2 holes 15mm from each end, and 2 more holes 35mm from each end (measuring from the center of the hole). See the “Aluminum Bar” STL for reference. I did it with a Dremel in a drill-press attachment for the first holes (small guide holes) then drilled bigger and bigger holes with a regular hand drill until I got to a 13/64" bit (which is perfect for M5 bolts). Also the nose must be epoxied onto the top piece. Check with your old battery before you epoxy it to make sure you have it aligned right!
I printed the top and bottom parts with a 0.8mm nozzle from ASA. I don't have an enclosure, so I printed it outside on a hot day in a cardboard box. This worked perfectly. The “nose” and other parts I printed from PETG with a 0.4mm nozzle because they either don't get much sun or are temporary.
I also included some very rudimentary battery holders. These are made to attach this battery to the aluminum bar with zip ties. This is a temporary solution while I make a better battery. It works, even though it is a 36V battery in a 48V bike. It’s just extremely finicky, slow, and has low range. I was able to find out what this battery came from and find the appropriate charger by googling “NEB1002-H1_V0.99D” which is printed on the BMS circuit board.
This project was inspired by this curved BH battery project.
License:
Creative Commons — Attribution — Noncommercial — Share Alike
11
zbuser
