About

Over the summer I got this folding E-bike as a project to repair. One of the things that needed to be done was to build a new case for the two lead acid batteries as the old one had many cracks and pieces of plastic missing.

Design

The case has a top and bottom piece. I would have liked it to be one whole piece with a lid but my printer is not tall enough. The bottom piece has holes for 5 M3 threaded heat-set inserts and the top piece has holes which align with them to clamp the two pieces together. I Ended up with 2 or so mm of clearance between the batteries and the case so I printed some TPU sleeves to help prevent excess movement. The original bike did not have any way to monitor the charge of the battery so I added a hole for a voltage gauge.

Final Thoughts

During the installation I wished that I had made it easier to tighten the 5 M3 bolts as it was a very tedious process. I am pretty happy with the case and the bike has been working well for almost a year as of writing this post.

Photos

Cad Model

Final Product