Hiding the wiring connectors and the controller

[Charliefox]

A couple of questions regarding the aluminium encased controllers that come with hub kits. How much heat to disperse from a 17amp 350W 9 mosfet model? I would like to hide it in a plastic case as in photo but not sure if it would overheat inside. I removed one end of the alu case to get it to fit better although it could be put back reversed. I will then attach the black box to the top tube..the only one anything like rounded.and free from cable fittings. Then what should I do with the bunch of wires with big connectors coming out of the back. Another smaller and narrower Maplin type case?? with a rubber grometted hole at each end. Of do you guys leave controllers open to cool breezes and strap them on using the 2 end plates.Not too keen on using plastic cable ties..to easy to cut and run! Any suggestions welcome.

 

[selrahc1992]

A couple of questions regarding the aluminium encased controllers that come with hub kits. How much heat to disperse from a 17amp 350W 9 mosfet model? I would like to hide it in a plastic case as in photo but not sure if it would overheat inside. I removed one end of the alu case to get it to fit better although it could be put back reversed. I will then attach the black box to the top tube..the only one anything like rounded.and free from cable fittings. Then what should I do with the bunch of wires with big connectors coming out of the back. Another smaller and narrower Maplin type case?? with a rubber grometted hole at each end. Of do you guys leave controllers open to cool breezes and strap them on using the 2 end plates.Not too keen on using plastic cable ties..to easy to cut and run! Any suggestions welcome. View attachment 10729 View attachment 10730

afraid this wont help - but i'm having the same problem - building a bpm/s12sm bike and wondered whether i could simply rivnut it to the (steelframed) bike and seal it with silicone (on top of the rubber seals) -whether this would be weatherproof? it would be better for cooling

 

[Charliefox]

afraid this wont help - but i'm having the same problem - building a bpm/s12sm bike and wondered whether i could simply rivnut it to the (steelframed) bike and seal it with silicone (on top of the rubber seals) -whether this would be weatherproof? it would be better for cooling

I don't fancy drilling for a rivnut as the Giant Frames are hydroformed with thinner metal in lower stressed areas. Trouble is I have no idea where these areas are. Also I may have to use the top tube as the down tubes are near triangular in shape and have awkward lumps...brake cable fittings..which through the box off line.I will use some very tacky Caravan sealant to stop any sliding about of the box. No chance at all for the battery in the frame. It will travel in a small rucksack or on a seat tube carrier.

 

[Deleted member 4366]

It won't do any harm to put a rivnut or two in the frame. The manufacturers normally put four in anyway, and they don't care.

How hot the controller runs, depends on a lot of things, so it's not possible to say whether it'll be OK, but I wouldn't worry about it unless you see your nice plastic case starting to melt, in which case it is running too hot.

 

[tongxinpete]

If the controller does run hot it would be possible to mount it in an adaptable box, (used in conduit wiring systems) These come in all shapes & sizes & are galvanized steel with a lid held down with screws in each corner. They can be mounted upright in the frame or on the handlebar stem. Could be fixed with small u bracket exhaust clips, conduit saddles, munson rings, or a large jubilee clip. I do like to get airflow over the controller or via the above box acting as a heatsink. That said I have a 6 fet KU 63 that gets barely warm to the touch even after a long hill climb, & a KU 60 generic controller that does get quite warm under exactly the same conditions. If you size the box right then all connectors will also fit in (good practice to tape them as box is conductive) ebay seems to be the best price on them if you only want one.
Controller can be screwed to inside of box to better conduct heat away