I have reasons for sticking with my original bike shop & order but thanks anyway.Blazing bikes say they have stock now,so might be worth cancelling with your dealer and ordering from them instead.
I have reasons for sticking with my original bike shop & order but thanks anyway.Blazing bikes say they have stock now,so might be worth cancelling with your dealer and ordering from them instead.
My range extender, ordered in July 2022(?) has just slipped to June.....
Cool project. I'm making a 14s1p battery from Samsung 50E. It should be 260Wh. I'm using a Bluetooth BMS for safety but it's not too bad to have a small pack like this without a BMS, especially the low power draw.I really find it hard to justify the cost of a range extender for this bike. In Australia, when the range extender becomes available, it will be $1,000.00 AUD with the required accessories. Decided to design my own and build it for a fraction of the cost (less then $50 using quality reclaimed cells). Of course you need a 3D printer but even factoring the cost of an entry level 3D printer that will do the job fine, still half the cost and you end up finally pulling the pin on that 3D printer that you always said you would get.
Teaser:
View attachment 114072
Basically it is 2 x 7S modules in series. Each module is individually wired with power and balance leads chased up the rectangle cavity to the top of the battery. I am only using the balance leads for periodic cell balance checking so no BMS with this design.
To be clear, this a getto design and should only be used at your own risk by people who understand the risks of home made batteries.
Important:
Your main battery and range extender battery need to be fully charged before pugging into each other. Absolute must.
Your bike must be switched on before pugging in the range extender. Absolute must.
If this worries you, do not even think about attempting this project. My recommendation is to purchase the OEM range extender that probably had 100s of thousands dollars thrown at it during R&D.
Moving on,
The design uses 18650 cells. Any cells that are are capacity matched will do the job. I am using NCR18650PF cells because they are easy to get and cheap. Plus they are 2.9ah and 10A which is plenty for this bike.
Because the range extender is parallel with the main pack, no low low voltage protection is really necessary. The bike will take care of this. 10% on the main pack will be 10% on the extender.
In regards to aesthetics, I have designed the battery to slot neatly into the standard Trek water bottle holder that comes with the bike. It looks like a water bottle and weighs between 800 and 900 grams.
Availability:
No, I will not ne making these for sale however, I will share the .stl files for printing once the project is completed if anyone is interested.
Printer is going flat out at he moment. I have the cells so give me a week to get this up and running. Wil update as the project progresses. View attachment 114076
I have been watching your progress and appreciate you sharing your work to date. Good luck with the 260Wh range extender. If you can give it an OEM vibe, I think it will be very popular.Cool project. I'm making a 14s1p battery from Samsung 50E. It should be 260Wh. I'm using a Bluetooth BMS for safety but it's not too bad to have a small pack like this without a BMS, especially the low power draw.
Happy to see some others out there making extended range packs for loads cheaper.
Yeah I'm limited with the Ego battery with how it looks. I'm going for a slightly different design, in order for a certain type of functionality (not saying yet as TQ might be watching ha!)I have been watching your progress and appreciate you sharing your work to date. Good luck with the 260Wh range extender. If you can give it an OEM vibe, I think it will be very popular.
Have you tried a trek dealer? That's how I got mine.Anyone know where to get a full size 360 wh battery (in the USA) ? I think I am going to go that direction instead of a range extender. An extra 2 lbs is nothing. That would give me 720 wh. I am really good with that.
Have you tried a trek dealer? That's how I got mine.
Mounting hardware is cheap. I don't swap it every ride but until now I have needed it on 4 rides. Nothing bad happens with swapping when you are careful.They are about 1 month out on the extra battery. I am not sure why, but my dealer said that Trek does not recommend using a second battery, stating it will wear out the mounting hardware and cable tray if taken in and out frequently. This sounds really stupid. Why advertise a removable battery if you do not want people removing it? Craziness. I am not sure I should worry about this, but don't want any warranty issues with Trek. I guess they would not know if you purchased and used a spare battery.
Sounds like a stupid statement by your LBS to me too. I take my battery out each and every time to charge it after each ride. I don't store the battery in the bike for fear of it potentially starting a fire in my basement. I charge and store in an old broken washing machine's steel tank that I already removed and tossed the plastic augar.They are about 1 month out on the extra battery. I am not sure why, but my dealer said that Trek does not recommend using a second battery, stating it will wear out the mounting hardware and cable tray if taken in and out frequently. This sounds really stupid. Why advertise a removable battery if you do not want people removing it? Craziness. I am not sure I should worry about this, but don't want any warranty issues with Trek. I guess they would not know if you purchased and used a spare battery.
I thought the statement sounded really stupid too. LBS said they had just spoke directly with Trek for another customer that wanted to do the same thing, cancel the order on the range extender, then buy a full battery. Not sure what any of them have to gain by those statements.Sounds like a stupid statement by your LBS to me too. I take my battery out each and every time to charge it after each ride. I don't store the battery in the bike for fear of it potentially starting a fire in my basement. I charge and store in an old broken washing machine's steel tank that I already removed and tossed the plastic augar.
Do you rotate batteries so they get equivalent charge and one isn’t siting with a charge for too long? Most of my rides wouldn’t need the extra battery.Mounting hardware is cheap. I don't swap it every ride but until now I have needed it on 4 rides. Nothing bad happens with swapping when you are careful.
I rotate them when I use them yes. Bike has done very close to 1000km in 2½ months now, and I have used the extra battery 4 times in that time. When I charge the extra battery again, I leave it at 80% and only charge the last 20% when I need to use it next day.Do you rotate batteries so they get equivalent charge and one isn’t siting with a charge for too long? Most of my rides wouldn’t need the extra battery.
Smart move. I plan to do the same. I have an Evoc Ride 12 back pack now and it is an outstanding build quality, so getting the Evoc FR Trail E-Ride backpack for a 2nd battery it would be a no brainer for me! With 2 batteries and 720 total watts that should get you plenty of power now.Just ordered an Evoc FR Trail E-Ride backpack. This with a full spare battery should be the perfect setup.
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Yep. That is my thoughts as well. 720 wh would be more than 2 range extenders. I’ll get 40 miles and 5,000’ elevation with using trail and boost mode, and very, very little eco mode, maybe 5%.Smart move. I plan to do the same. I have an Evoc Ride 12 back pack now and it is an outstanding build quality, so getting the Evoc FR Trail E-Ride backpack for a 2nd battery it would be a no brainer for me! With 2 batteries and 720 total watts that should get you plenty of power now.
Just contemplating the pack and a battery and ~1,100 bucks on your back. Ouch!Just ordered an Evoc FR Trail E-Ride backpack. This with a full spare battery should be the perfect setup.
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