The Lectric XP Step-Thru (Both 2.0 and 3.0 use the same battery) has a massively long battery, and there isn't a really great way to strap it to the bike itself. I wanted something that I could securely strap down so I wouldn't have to worry about the battery bouncing around, or getting wet in the rain.
I designed this to fit snugly in the front basket. For me, the handlebars are up high enough that the battery can fit underneath, so it doesn't stick out. But you can mount this as you see fit. The case may bounce around a bit as you hit bumps, so I created a “sacrificial plate” that will absorb most of the impact. It has cutouts for the official front basket, and zip tie holes.
Parts Required:
- Foam padding. I got mine at my local Joann's. You'll want something with some good cushioning, but something smooth if at all possible to make it easier to slide the battery in and out. My padding is about 9mm thick - if you use something of a different size, you'll probably want to edit the parameters of the model.
- CA glue - You want a strong bond between the printed parts. Something like this works well.
- Foam adhesive. Something like this works well.
- Outdoor duct tape - Something like this.
- VHB tape - Such as this.
- Zip ties
Assembly:
- Print out all the parts, ideally in PETG for greater strength and outdoor temperature resistance. Three walls or more for extra strength, but if you're also wrapping the case in duct tape, that will also give some extra strength. For the sacrificial plate, I recommend using more top/bottom walls and a higher gyroid infill.
- Glue the three bottom parts together, and the three top parts together, using CA glue. Wait for them to dry.
- Cut out foam and do a test fit to make sure it fits well on all 5 sides. I used two layers of foam at the bottom, since that's where the bulk of the battery weight will be.
- Glue the foam to the top and bottom sections. Wait for it to dry.
- Glue the top and bottom parts together with CA glue. You might want to use some duct tape to hold the parts in place and under pressure so they form a good bond.
- For water resistance and to add extra strength, wrap the case in outdoor duct tape.
- Attach the sacrificial plate to the bottom using VHB tape. (Don't glue this - if you need to replace it in the future, VHB tape is far easier to get off)
- Zip tie the case to your bike. (I like these zip tie plates. You can VHB them to the case.)
Software2
