Ebike Battery Tank

petehouk · Oct 20, 2023

Hey everyone. I am in the process of building an ebike starting with a Schwinn Corvette frame. I found a 10 ah battery pack that will fit in the "tank space" of the frame. Now...how to get a tank around it? I have some rudimentary metal working skills and tools but this looks like a really complicated shape to try and make. But this feels like the right place to put the battery instead of scabbing it on in a bag or on a rack.

Pictures of the battery in two slightly different positions are attached. The third top view shows how far this battery sticks out beyond the tubes of the frame.

Link to battery:
https://www.electrifybike.com/colle...0ah-samsung-21700-50s-mini-max-e-bike-battery

Captain Awesome · Oct 20, 2023

@The Renaissance Man is the resident tank guy

The Renaissance Man · Oct 20, 2023

Being that it is a canti Schwinn frame, I would start looking for a Phantom/Corvette after-market tank to use.

But if you want to make something custom, sculpt what you want and make a fiberglass tank.

JennieDraegon · Nov 11, 2024

If you are really bold, look at designing a 3d print tank. That's what I am looking at. Trying to make it look like a teardrop harley setup.

Eridez · Nov 24, 2024

Shape some styrofoam to outline the shape then wrap the whole area in kitchen Cling wrap, stretch cheap fuzzy polyester fabric over it, use a paint brush to soak the fabric with epoxy resin and then cut it off to make a base to work from. You can build up layers for thickness then shape and finish.

JennieDraegon · Nov 25, 2024

JennieDraegon said:
If you are really bold, look at designing a 3d print tank. That's what I am looking at. Trying to make it look like a teardrop harley setup.

Added note. Going with the 3d printed, so I can print more for later builds.