DIY EBike Battery Pack

In this project I will show you how to combine Li-Ion cells, nickel strips and a BMS (Battery Management System) in order to create a battery pack for an EBike. My pack has a voltage of 48V, a capacity of 5Ah and an output current of 20A but you can easily add more cells to alter those values. Let's get started!

Step 1: Watch the Video!

The video gives you all the information you need to create your own EBike battery pack. But I will present you some additional information in the next steps.

Step 2: Order Your Components!

Here you can find a parts list with possible example seller (partly affiliate links):

I used the kWeld spot welder: https://www.keenlab.de/index.php/product-category/...

Ebay:

26x INR18650-25R: http://rover.ebay.com/rover/1/711-53200-19255-0/1?...

13x Spacer: http://rover.ebay.com/rover/1/711-53200-19255-0/1?...

7mm x 0.3mm nickel ribbon: http://rover.ebay.com/rover/1/711-53200-19255-0/1?...

13s 20A BMS: http://rover.ebay.com/rover/1/711-53200-19255-0/1?...

10 AWG Wire: http://rover.ebay.com/rover/1/711-53200-19255-0/1?...

Aliexpress:

26x INR18650-25R: https://s.click.aliexpress.com/e/_dY2Dqpb

13x Spacer: https://s.click.aliexpress.com/e/_dVZZNeh

7mm x 0.3mm nickel ribbon: https://s.click.aliexpress.com/e/_d6k3sXr

13s 20A BMS: https://s.click.aliexpress.com/e/_BfZtptat

10 AWG Wire: https://s.click.aliexpress.com/e/_dYeiEM1

Amazon.de:

26x INR18650-25R: https://amzn.to/2jjQEiV

13x Spacer: https://amzn.to/2r7EMny

7mm x 0.3mm nickel ribbon: -

13s 20A BMS: https://amzn.to/2vSl1Ws

10 AWG Wire: https://amzn.to/2HzcXPS

Step 3: Build the Battery Pack!

Since the battery pack simply consist of straightforward parallel and series connections there is not much to say about it. But if you need extra help you can use the here shown pictures as a reference.

Step 4: Success!

You did it! You just created your own EBike Battery pack!

Feel free to check out my YouTube channel for more awesome projects: http://www.youtube.com/user/greatscottlab

You can also follow me on Facebook, Twitter and Google+ for news about upcoming projects and behind the scenes information:

https://twitter.com/GreatScottLab

https://www.facebook.com/greatscottlab

Comments

[bobbilll]

Scimmed over balance wires, (nothing) re where how many...why.is not enough. What if one uses plate to make parellel/series connection tween 4-5 cell sets?

[stumpybir]

İf u can use serial and parallel for circuit ; u can double power and current but your need double battery for this!
Ure use all serial = 1 hours working battery
if u use serial and parralel circuit( together) =minimum 2 hours working
[if your 1 battery fails not work your circuit but if u make i said always work]

[marcobm10]

great job bro, but i need a little thing, can you upload a photo showing one side of the nikel strips and the other side, is the last thing i neeeeed !!!!! :(

[mohityadav0928]

Hey, I like your video on manufacturing a battery pack. Have you made the video on BMS? Could you suggest me the video series or reading material on BMS? Btw great video