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Nice looking bike. I'd do as you suggested using a rigid plastic plate, zip tie the cells+BMS pack to the plate inside the bag and then.... rub the inside of the bag with a damp sponge and squirt building foam all round the pack. That way you get thorough waterproofing without a shower cap, a...

"dual battery adapter" finds them from £27 including postage. @Cisco-man At 7A it would shed 3.5W so could need a heatsink depending on your setup. If the bolt touches the diode case the nut carries battery +ve which shouldn't be a problem but I'd cover it. Very neat!

Like you I'd guess the transistors will be compatible voltage-wise but could have different pinout, a component tester should sort that out, or a meter will ID the base and you've 3 spares. Fully charged 36V is 42 actual volts, 48V LVC could be 40V or 41V. Controller might turn off if it...

Sounds OK to me. Near to full the charging slows down so take a good estimate - your 3 hours - then add an hour or two to finish off, and if still red give it all day on this occasion to balance up. If you haven't noticed range fading a lot it's pretty certain all's well whatever the final...

Above with mixed cell types more current comes from one than the other and the ratio of their contributions changes and reverses during discharge. This also happens below using identical cells with differing resistances, in this case interconnect resistances. Below with mixed cell types when...

My sarcasm went a bit overboard perhaps but impediments to charging curtail the utility of ebikes and that must affect their uptake. Anyway, what's the public's take on battery fires where you are (presuming still Austria) and how are the authorities responding? It's been said that our fires...

Thanks for that, did some digging and LEVA-EU have this to say about anti-tampering: "It has also appeared that the anti-tampering measures in the standard need to be improved. The wording is unclear and the requirements themselves go against EU policies. For instance, manufacturers should give...

By 2 piece pattern I was thinking of your CNC part but in 2 overlapping pieces, using the two 5mm eyelets and not a jubilee clip. Then precise orientation of the 3 holes and the flats is no longer critical, in fact the holes can be oversize, exhibit waterjet taper and what not. Just take out...

The cheap convenient gizmo is that same item, it could either cut the charger (NC contact) or power a second alarm (NO contact). But recall saneagle's wise words, basically you need to be sure that safety gear's reliable.

Who was it who tried to introduce a tamperproofing clause and through which means? It may have a place but I think its proponents need to be aware of better safety measures, and would we want to be driving tamperproof horsecarts these days?

So to paraphrase the CSA briefed the IO, the IO examined the charger and battery and briefed the Coroner who officially concluded they probably didn't match. Bike chargers and batteries of 36V and 48V look very similar before they're burnt, although in this case the parts may have been...

Hang on, aside from the hole clearances that's a zero tolerance part. Are the holes slightly oversized as a simpler alternative to arc-ed slots? That would work but the torque limit for the 5mm frame threads will be low. Maybe it's wiser to follow the traditional 2 piece pattern with high...

Nice, how did you transfer from printed template to steel accurately, especially the hole with the flats?

Here's AlanB's TA done as saneagle prescribes: and my Hammer arm done in the same sequence. You want an arm of the TA snug against whichever eyelet so as not to exert leverage on the 5mm threading.

Meths is what I'd try for loosening the collar, or failing that water with a drop of detergent.

You're describing a fault within a cell, while I was saying a BMS is unfit if it can't prevent damage through over-charging, an external factor. The BMS controls the electrical interface to the outside world i.e. the battery ports; it doesn't have that control over physical events like cell...

No the over-voltage sensing is at cell level (which I should have written) so I think you'd need 2 cells in a P group to fail simultaneously to go undetected. I think temperature sensing should always be at multiple points throughout the pack, as some batteries are, because both internal and...

Yeah they could be clearer. Is the Yose's range worth the cost of a mixer? You wouldn't need the mixer if you take the pins out of the Yose sled or rehouse the controller in a 'ABS project box'.

A pair of templates expose either all the + slots... There's probably a tactful admonishment on the reverse :)

In my own tribute to Flecc's "EAPCs/Pedelecs vs the rest" crusade (to get that distinction widely used and into the media), I want to propose that we call rubbish batteries Cell-packs. Any safe BMS protects against over-voltage, over-current in and out and over-temperature, plus other functions...