Help! Frame battery without bottle cage screw holes

Oldie

Pedelecer
Mar 29, 2013
151
41
Scotland
My Hailong battery came with some "feet" to match the curvature of the frame. They work well although I also added a heavy duty removable zip tie just to cope with uneven surfaces. Feels rock solid.

 

Woosh

Trade Member
May 19, 2012
20,381
16,878
Southend on Sea
wooshbikes.co.uk
Thanks for posting the pictures. You can install the battery on the main tube or the seat tube but I wouldn't recommend either. Best solution is to replace the rack and install a rack battery.
 

Nealh

Esteemed Pedelecer
Aug 7, 2014
20,917
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West Sx RH
Wolf tooth do this, I have not used any of these:


Giant also do this

The B rad still needs riv nuts to hold a battery.
 

saneagle

Esteemed Pedelecer
Oct 10, 2010
6,842
3,169
Telford
You can still fit ot on the frame, but you need to make a support for it, which is pretty easy. Put the riv-nuts in first, then wrap the frame in cling-film. Also, wrap the battery mount in cling-film. Slap a few layers of fibreglass on the frame, then screw down the battery support to squish it right down before it sets. Add in a load more pieces underneath to make a fillet parallel with the sides of the frame. When it's all set, use a saw and/or angle grinder and/or sandpaper to make it nice and neat. You can see how I did it here on my Dahon ten years ago:

 
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guerney

Esteemed Pedelecer
Sep 7, 2021
11,424
3,247
You can still fit ot on the frame, but you need to make a support for it, which is pretty easy. Put the riv-nuts in first, then wrap the frame in cling-film. Also, wrap the battery mount in cling-film. Slap a few layers of fibreglass on the frame, then screw down the battery support to squish it right down before it sets. Add in a load more pieces underneath to make a fillet parallel with the sides of the frame. When it's all set, use a saw and/or angle grinder and/or sandpaper to make it nice and neat. You can see how I did it here on my Dahon ten years ago:

That's a brilliant thread and conversion, and one I hadn't seen. Do you still use that Jetstream? Converting my Dahon Espresso (a £72 ebay "bargain" bought on ebay a few weeks ago, alumunium frame, front steel fork, renovations ongoing) with a rear hub motor looks like a lot of work... if anything, I may go with a simpler front hub motor build for that one. The BBS01B has ruined my fitness, so I probably will very likely leave the Espresso unelectrified, get some actual exercise, because it's a certainty I will use any electrical assistance to the legally allowable max!


 

saneagle

Esteemed Pedelecer
Oct 10, 2010
6,842
3,169
Telford
That's a brilliant thread and conversion, and one I hadn't seen. Do you still use that Jetstream? Converting my Dahon Espresso (a £72 ebay "bargain" bought on ebay a few weeks ago, alumunium frame, front steel fork, renovations ongoing) with a rear hub motor looks like a lot of work... if anything, I may go with a simpler front hub motor build for that one. The BBS01B has ruined my fitness, so I probably will very likely leave the Espresso unelectrified, get some actual exercise, because it's a certainty I will use any electrical assistance to the legally allowable max!


No, I converted it back and sold it about 4 years ago. It worked best at 44v (12S) with an AKM 100 cassette motor. I did a few long rides, but then it got relegated to only getting used when I had my car serviced. Now I have a van, so can use a full-size bike.
 
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Waspy

Esteemed Pedelecer
Sep 8, 2012
433
171
On the subject of Rivnuts, I used RJ The Bike Guy's cheap method that requires no expensive Rivnut tool.
 

saneagle

Esteemed Pedelecer
Oct 10, 2010
6,842
3,169
Telford
On the subject of Rivnuts, I used RJ The Bike Guy's cheap method that requires no expensive Rivnut tool.
That's not a good way. It can work, but more times than not, the riv-nut starts turning with the screw, and if the rivet has already started to form, you can end up with that lot stuck in the hole and a very tricky procedure to get it out. Also, there's nothing holding the riv-nut down, so it can lift a bit and look very ugly when done. The two strips of metal with holes in is much better, as it doesn't involve turning the riv-nut, and it holds the riv-nut down while forming the rivet.
 
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Waspy

Esteemed Pedelecer
Sep 8, 2012
433
171
That's not a good way. It can work, but more times than not, the riv-nut starts turning with the screw, and if the rivet has already started to form, you can end up with that lot stuck in the hole and a very tricky procedure to get it out. Also, there's nothing holding the riv-nut down, so it can lift a bit and look very ugly when done. The two strips of metal with holes in is much better, as it doesn't involve turning the riv-nut, and it holds the riv-nut down while forming the rivet.
Fair enough, I'll bookmark this thread for the future. Thanks.
 

pettie

Just Joined
Oct 6, 2024
1
0
Right, here's a picture of the bike. The frame is very elliptical, which might be why Dawes didn't provide screw holes.

Thanks for the suggestions of alternatives. The straps would probably hold a bottle & holder in place, but may not be beefy enough for a heavy battery.
Did you find a solution? I've got the sane bike I want to convert, thanks
 

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