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Hello theshade, You are correct, the diode only serves to block reverse current, but in no way limits the current delivered by the extender battery to the main battery. Remember that this extender approach is in parallel with the main battery, and therefore some very strict conditions of use...

Hi Antonny, I have made an extender for Orbea Gain D50 working in parallel with the main battery. In fact the parallel approach work well sharing the load demanded by the the motor. It is not a charger so some initial conditions must be taken into account to avoid main battery damage. Agree with...

Hello, I have observed that the % of remaining charge recorded during the trip does not correspond to the half of main battery as if the extender did not exist. (But actually the main battery and the extender are both contributing half). This causes the system to disconnect due to a low level of...

Hello, I am attaching a draft of the test 3 that I carried out on my the DIY Extender.

Hello, I am attaching a STL file if you want to print in 3D a lid (mimics a bottle) for the DIY extender. This is a cosmetic upgrade but it looks good. PD: Pedelecs does not allow me to attach STL files, contact me and send me your email address if you want to receive that file.

Yako, I really appreciate your offer. My days of R&D engineer belong to the past, I am old and just want to enjoy my last days doing cycling. DIY extender was my contribution to your initial project. Enjoy the extender and have very nice rides with more battery capacity. Do not hesitate to...

DIY Extender is made to provide current to the motor not to charge the main battery. This is safety and friendly operation mode ( sharing the load with the main battery) . I think that Mahle Extender works in another way, but for me it is not the case. The DIY is a system that works perfectly...

Yes I did, but I avoid that condition because Extender provide current to the Main battery . This scenario is no necesary to use.

Hi Yako, I have readings where the motor is drawing 7 amps and the extender is providing more than 3 amps. In my opinion (based on measurements and not assumptions) the DIY Extender works in parallel with the main battery once the extender is equalized with the main. (this happens very quickly)...

Hello, I am attaching a draft of the test report that I carried out on my the DIY Extender.

Hello, I am attaching a draft of the test report that I carried out on my the DIY Extender.

Yako, send me your email address.

Hi Yak, more than that. The mistery now is complete clear. Diy Extender has almost 90km road real test and I am putting all my tests and results in a report.

DIY Extender already finished and installed. After 44 Km on road test, The behavior of the currents and voltages of the Extender and Main Batt, were equal to the measurements in the static test with route simulation in Rouvy and using the Wahoo smart trainer, therefore the project is finished...

DIY Extender already finished and installed. After 44 Km on road test, every thing worked as expected. Very saticfatory results, so Proyect is over. If someone need help please send me PM.

The first basic measurement we will make in the actual DIY extender and main batt bank will be to charge separately up to 100% (when the charging current is < 20 mA the ammeter used will mark o mA) both batteries. After completing these charges up to 100% on both batteries we will take note of...

Here we can see the adaptations and connectorization for the DIY extender. M2 is an adapter to charge the DIY extender batt with the same Mahle charger that we use for the main batt. This is optional.

The following image shows a cheap and useful instrument to which I have put a connector compatible with the ones we will use in the DIY extender. We can measure voltage and current simultaneously.

Next I will show a series of images about the construction process of the DIY extender. A series of manual modification work was necessary but nothing that cannot be achieved with patience and care.

Support information on internal resitance. Test of Sanyo NCR18650GA 3500mAh (Red)...