DIY E-bike Battery || Assembling 48V Hailong Battery

Hello, fellow makers!

In this instructables i will add extra insights for my tutotial on how to assemble a Hailong battery(48v) for E-bike battery.

BE SURE TO CHECK OUT THE VIDEO FOR THE ASSEMBLING PROCESS.

And if you want more details you can see my instagram handle @hyper_makes

Happy Making!

I AM PROVIDING THE LINKS TO THE PARTS AND THINGS I USED ** WHICH ARE NOT AFFILIATED**

Hailong 48V Battery case : HERE

18650 Li-ion cells EV grade 3C discharge rate : Local supplier

54.6V 4A Charger : HERE

Spot Welder : HERE

BMS(13S 60A) : BE SURE TO CHECK THICCNESS BEFORE ORDERING HERE

Silicone Wires : HERE

Insulation Gasket : HERE

TOOLS REQUIRED :

Soldering Iron

Solder wire

Solder flux

Hot glue gun

Wire stripper

Kapton Tape

Before you order your BMS(Battery management system) circuit be sure to check its thiccness because there is very little space inside the case.

ALSO CHECK YOUR MOTOR CONTROLLER FOR MAX CURRENT OUTPUT. MINE HAS 45A(MAX) CURRENT RATING SO, THE NEAREST BMS I FOUND HAS 60A(MAX) OUTPUT.

**ALSO THE BMS CONNECTING WIRES SHOULD BE SOLDERED FIRST TO THE NICKEL SHEETS BEFORE WELDING THE SHEETS TO CELLS.**

SPOT WELDER SHOULD BE SET TO 300 MILLI SECONDS MODE FOR GOOD WELDING JOINT.

Follow the correct welding diagram given with the battery kit. IF NOT THEN GOOGLE ABOUT YOUR BATTERY CONFIGURATION AND FIND CORRECT DIAGRAM. EXAMPLE IN MY CASE : 13S5P CONNECTION DIAGRAM.

Mask the battery properly so that it is safe from any kinds of short circuits and accidental shorts.

IMPROPER MASKING OF BATTERY CAN LEAD TO FIRE ACCIDENTS AND DEAD BATTERY.

Do the wiring according to the diagram provided with kit you bought or google about it.

THE PHOTOS I HAVE PROVIDED ARE JUST COMMON EXAMPLES ON HOW TO DO WIRING AND CONNECTION.**PLEASE CHECK IT WITH YOUR BMS AND BATTERY IF YOU ARE GOING TO FOLLOW!**

Snugly fit all the wires at the edges of the case so that you can close the lid of the case properly.

Hot glue wires in place for more secure fit.(If necessary)

That's it. You have assembled your own e-bike battery. Check video if you are stuck somewhere.

STILL IF YOU HAVE ANY KIND OF QUESTIONS, BE SURE TO COMMENT DOWN BELOW. I WILL TRY MY BEST TO HELP YOU OUT. :)

Happy making!

The switch provided in the battery case is rated for AC applications only and can't handle large currents for DC applications, thus making it a potential bottleneck for the current flow. The switch **can burn easily** in this high current application when you will use the hub motor at full power.

SO I RECOMMEND NOT TO USE THE SWITCH IN WIRING THE OUTPUT WIRES. IF YOU HAVE ALREADY WIRED THEN YOU CAN SIMPLY SHORT THE THE PINS WITH 12AWG WIRES TO BRIDGE IT.