E-Bike Battery Spacer

thingiverse

I made this part to adapt an older (still good) battery for an e-bike. Spent way too much time looking through Amazon, Aliexpress, and eBay for one that matched the existing 4-pin and length but that was next to impossible (at a fair price). So I ordered a longer one and this shim made the batteries interchangeable. You may have to elongate the wires for the low/full gauge, but these had so much slack I didn't have to. I would recommend adding a nonconductive filler inside to keep the batteries from sliding up and down causing potential fatigue or failure. This adapter is a snap-fit to the battery. 91mm OD 87.5mm ID & a 1mm lip female top and male bottom. I needed a 25mm spacer and longer screws by the same amount. M3x50mm worked for me and Home Depo had them on hand. I used an XT60 (an XT30 would have worked for the 15 amps this controller can actually put out) to adapt the new harness to the existing controller. CAUTION, there is a remaining charge in the controller so cut and solder 1 wire at a time. After it's mounted to the frame I had to trim the bottom cup to fit the old battery that had different locations for the on-off switch and charging port.