E-Bike Controller Enclosure (For 1000W DIY Systems)

thingiverse

THIS IS A WORK IN PROGRESS, PLEASE CHECK BACK FOR REGULAR UPDATES AND EXPANDED MATERIALS (ASSEMBLY DRAWINGS, BOM, COMPATIBLE CONTROLLER DRAWINGS, ETC.) NOTE: Please refer to the included reference images for compatible controllers and products! ------------------------------------------------------------------------------------------------------------------------ This sleek motor controller enclosure takes minimal space on your frame and comfortably mounts your most critical component for long-term use. No more controller bags or cable-ties, no more chaotic wire management! This design is intended to enclose and mount a compatible (1000 Watt DIY Kit) E-Bike Controller onto "standard" bicycles with ~1.75" (44mm) cylindrical (tubular) frames. The enclosure references extruded profile design philosophies in order to capture, align and secure an off-the-shelf 1000 watt brushless electric motor controller between the upper and lower frame tubes of most standard bicycle designs. Two side cover plates allow for easy access to internal wiring and connections. Each cover plate also features a generous vent window, for proper thermal transfer during extensive use. To make implementation simple, all hardware is M3, due to ease of access and low cost. The main "extrusion" (enclosure) readily accepts M3 threaded inserts for securing each cover plate. If you have a more specific application, a Parasolid assembly is included within the Thing Files for ease of remixability. ------------------------------------------------------------------------------------------------------------------------ This design is part of my (sort of) expanding list of E-Bike conversion products, please check below for links to additional designs! I will update this list once more are available. Battery Rack Upper Mounting Blocks: https://www.thingiverse.com/thing:4830160