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Product Showcase / Wattcycles Tube Battery Version 2.0
« Last post by Tom Cole on August 13, 2017, 11:05:38 am »
So this is almost ready.  I've redesigned the tube battery to make it smaller, lighter, less expensive, and with a slightly longer range.  Oh and this one look cool because the outer case is transparent!  That's right, you can see the actual cells!

Basically, a change in battery chemistry allowed me to switch from a 10s4p to a 10s3p due to an increase in capacity and amp output.  The idea of the design is still the same, but reducing the total cells from 40 to 30 means an approximate 25% decrease in diameter, weight, and cost, yet the capacity is theoretically 5% greater!

The reduction in cell count means that each layer of the battery has two fewer cells, so I was able to rearrange them to fit in a smaller diameter CLEAR thick walled PET tube.  This tube is a little more expensive than PVC, but the "cool factor" payoff is worth it.

I've finished the main design including wiring up the BMS and I am about to do some burn-in testing before closing everything up.  While out riding the other day with it, I popped a rear tire and rode 2 miles on a flat rear tire at 17 MPH without pedaling!  The battery and the wiring did not overheat, so I'd say initial tests are very promising.

Here's a pic with the new battery on the bike and the previous version on the floor.
Coffee Shop / CNC machine I built
« Last post by Tom Cole on February 01, 2017, 03:36:22 pm »
I thought some of you might like to see this.  It is called a "Mostly Printed CNC" because all the plastic parts are 3D printed.  The files needed to print the parts are FREE! The metal rails are plain cheap 3/4" emt conduit.  The electronics can all be bought inexpensively online if you can configure them yourself or for a little extra from the machine's designer. I bought most of my electronics and tool bits from him to support his development efforts.

Here is a video of mine:

Ride, Trail, and Club Announcements / Phenomenon Trail - Ft Gaines, GA
« Last post by Tom Cole on December 20, 2016, 11:12:39 am »
This is a 4 mile paved running/hiking/biking/golf cart trail that goes from the lodge parking lot at George Bagby state park to the East Bank public use area (Corp of Engineers) parking lot just north of Fort Gaines, GA along the beautiful Lake Walter F .George (aka Lake Eufaula).  It is mostly flat and fairly shaded.
Ride, Trail, and Club Announcements / Chehaw Trail - Albany, GA
« Last post by Tom Cole on December 20, 2016, 11:07:26 am »
Chehaw Park in Albany, GA has a great 11.25 mile MTB trail.  The trail has several loops that allow shorter rides.  I have ridden this trail with my ebike and although I pedaled most of the time, there were several instances where I was very happy I had a little help when I needed it.  Cost to get in the main park is $3.21 including tax and I think the trail is well worth it.
The park also has a camping area, BMX track, AWESOME playground and a wild animal park built by Albany's own Jim Fowler of "Wild Kingdom" fame.
In The News / New Battery Tech: Five X energydensity @ one-fifth the cost
« Last post by Tom Cole on December 05, 2016, 07:17:54 am »
Product Showcase / Re: Teasers of a battery I'm designing.
« Last post by Tom Cole on November 04, 2016, 08:00:46 am »
This project is done and available here for free:
The attached zip folder contains 3d printable files, Fusion360 CAD files and (incomplete) instructions to make a 36V 10S4P electric bicycle battery pack using 18650 batteries that actually measure 18mm dia.  A video and further instructions will follow later as I do a redesign for slightly larger diameter 18650 batteries.

This project is open source.  The files are free to print and you may sell the prints and completed battery packs using this project and it's files.  You MAY NOT sell the files.  All I ask for my efforts is that you include "Wattcycles Tube Battery" in the name and that you mention as the source.

Update 11/8/16 I added the Fusion360 files so you can edit as you need and added some comments in the instructions based on my own completed battery experience.

Everything in and/or about this project is "use at your own risk."
Product Showcase / Re: Teasers of a battery I'm designing.
« Last post by Tom Cole on November 02, 2016, 08:16:03 am »
Further model changes...getting closer!
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