Wiktor Wise
Building your own electric skateboard battery can be a fun and rewarding project, but it requires careful planning and execution. The battery is a crucial component of an electric skateboard, and it can also be the most expensive part. In this guide, we will cover the steps to build a safe and effective electric skateboard battery, including choosing the right type of battery cells, assembling the battery pack, and ensuring it is properly protected and weather-resistant. We will also discuss the advantages of building your own battery versus buying a pre-assembled one, as well as the potential challenges and risks involved. By the end of this guide, you should have a clear understanding of how to build a high-performance electric skateboard battery that suits your specific needs.
Characteristics and Values of an Electric Skateboard Battery
| Characteristics | Values |
|---|---|
| Battery Type | Li-Ion |
| Battery Voltage | 10S or 12S |
| Battery Capacity | 11Ah |
| Battery Cells | Samsung 18650 cells |
| Battery Configuration | 10S2P or 10S4P |
| Battery Life | 30-60 minutes |
| Battery Size | Slim |
| Battery Housing | Shock-proof and weather-resistant |
| Battery Charging | BMS eliminates the need for a balance charger |
| Battery Connections | XT90 connectors |
| Battery Mounts | Custom locations |
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What You'll Learn
Sourcing battery parts
First, decide on the type of battery you want to use. Li-Ion batteries are a popular choice for electric skateboards, and you can choose to make your own Li-Ion pack or even use batteries from a drill, as suggested by some DIY enthusiasts. If you opt for a Li-Ion pack, you'll need to purchase individual cells and assemble them into a pack. The number of cells required will depend on the voltage and capacity specifications you desire.
When sourcing battery cells, it's essential to consider their quality and performance. Look for reputable brands like Samsung, which offer cells rated for continuous discharge, ensuring your battery can provide sufficient current for your skateboard's needs. You can find these cells online or through specialised battery retailers.
To assemble your battery pack, you'll need additional parts like connectors, a battery management system (BMS), and possibly a soldering kit or spot welding equipment. Connectors such as XT90 connectors are used to link the battery to the skateboard's electrical system. The BMS helps protect and manage the battery, and it may eliminate the need for a separate balance charger.
Before purchasing parts, it's advisable to familiarise yourself with the specific requirements of your electric skateboard build. Refer to online forums, such as the esk8 forum, and YouTube videos for detailed guidance on part selection and assembly. Additionally, some websites like Mboards.co offer a handy kit builder function to ensure you don't forget any necessary components.
Lastly, remember to consider the size, weight, and portability of your battery setup. If you intend to travel with your skateboard, ensure that the battery complies with TSA regulations, like the 5Ah 20V DeWalt batteries that are within the allowable limits for carry-on luggage.
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Soldering and welding
For those who are comfortable with spot welding, it is important to ensure that you have the necessary equipment and safety precautions in place. Protective gear, such as eye protection and heat-resistant gloves, is essential when working with welding equipment. Additionally, it is crucial to work in a well-ventilated area or use fume extraction equipment to mitigate the risks associated with welding fumes.
The process of spot welding involves creating a series of small, precise welds to join the battery components securely. This technique is commonly used in battery building due to its ability to produce strong and reliable connections without generating excessive heat that could damage the sensitive battery cells. It is important to have a steady hand and a good understanding of the equipment to ensure accurate and consistent welds.
Practicing on similar materials before attempting to weld your battery components can help you get a feel for the process and improve your technique. Additionally, it is important to follow manufacturer instructions and industry best practices to ensure safe and effective welding. Taking the time to prepare and understand the process will help ensure a successful and safe battery-building project.
Overall, while soldering and welding are crucial aspects of building an electric skateboard battery, it is important to prioritize safety and follow recommended practices. For those who are new to welding or prefer alternative methods, no-weld battery kits offer a viable option that eliminates the need for specialized welding skills and equipment. By considering your skills, resources, and comfort level, you can make an informed decision about the best approach for your project.
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Battery configuration
However, if you're looking for more flexibility in terms of voltage and current, building a custom battery pack might be preferable. Li-Ion battery packs are commonly used in electric skateboards, but the individual cells can be expensive, and assembling them safely requires some expertise. When configuring your battery pack, you'll need to decide between series and parallel connections. Connecting batteries in series increases the voltage while keeping the current the same, which is useful if you're looking for higher speeds. On the other hand, connecting batteries in parallel increases the current and overall battery life without changing the voltage, which can be advantageous for longer rides.
For example, with 5Ah 20V DeWalt batteries, you can connect two in series for 10S2P, similar to many production electric skateboards. Alternatively, adding another two in parallel results in 10S4P, providing greater range and current capabilities. It's important to consider the discharge rates and overall power output of the batteries to ensure they can deliver the required current safely. Additionally, the physical configuration of the battery pack is important. Some builders prefer a single-layer configuration for a slim design, but this may require special consideration to manage heat and current handling.
When assembling the battery pack, soldering and spot welding are common methods of connecting the cells. However, soldering directly onto 18650 cells is not recommended due to the risk of heat transfer damaging the cells. Instead, consider using nickel strips or specialised battery kits that eliminate the need for soldering altogether. Finally, don't forget to enclose the battery pack in a shock-proof and weather-resistant case to protect it from the elements and any potential damage from riding.
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Battery safety
Electric skateboards are capable of high speeds, and can therefore be extremely dangerous. While safety features and gear can help mitigate the risks, it's important to be aware of the potential dangers and take precautions to ensure a safe riding experience.
Lithium-ion batteries are the most common power source for electric skateboards due to their high energy density, quick charging capabilities, and lightweight design. However, they are sensitive to overcharging and overheating, which can reduce their lifespan and pose safety hazards. To ensure battery safety, always use the charger provided by the manufacturer and avoid leaving the battery unattended or charging overnight. Charge the battery indoors in a dry, temperature-controlled environment, and unplug the charger as soon as it's fully charged. Regularly inspect the battery, charger, and charging cable for any signs of damage or wear and tear, and replace them if necessary. Keep the battery active by using your electric skateboard regularly and follow the manufacturer's guidelines for proper maintenance and storage.
In addition to battery safety, it's crucial to prioritize personal safety while riding electric skateboards. Always wear full protective gear, including a helmet, knee pads, elbow pads, and wrist protection. Choose gear that doesn't interfere with your control of the remote. Be especially cautious when children are riding electric skateboards, as they may not have the same level of control or experience as adults.
It's important to note that electric skateboards lack mechanical brakes, which can be a safety concern, especially at high speeds. Always ride at speeds where you can stop using normal skateboard techniques like foot braking. Stay within the advertised top speed of your electric skateboard, especially when riding downhill, to avoid losing braking power.
By following these safety precautions and staying informed about the maintenance and function of your electric skateboard and its battery, you can minimize potential risks and enjoy a worry-free riding experience.
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Battery charging
If you choose to build your own battery pack, you will need to decide on the configuration. The number of cells, voltage, and capacity will depend on your specific requirements and preferences. For example, if you want a longer range, you may need to add more batteries in parallel. It's important to ensure that your battery can handle the current and stay in contact while riding. Some people solder copper wire to nickel strip tabs and then spot weld the assemblies to the cells, but soldering 18650s is generally discouraged as it transfers too much heat to the cells.
There are several battery kits available that can help you avoid spot welding, such as the Vruzend battery kit or the No-Solder 18650 battery kit. These kits may not offer the slim design you are looking for, but they can provide a safer and more convenient option for building your own battery pack.
When it comes to charging your battery, it's important to consider the advantages of different methods. For instance, a BMS (Battery Management System) may eliminate the need for a separate balance charger. This can simplify your setup and reduce the number of parts required. Additionally, some batteries, like the 5Ah 20V DeWalt batteries, are easily removable, making them convenient for travel as they comply with TSA limits for carry-on luggage.
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Frequently asked questions
There are several online forums and YouTube videos that provide detailed guides and tutorials on building electric skateboard batteries, such as the esk8 forum, the Endless Sphere DIY EV Forum, and YouTube channels like JayDLawrence.
It's important to consider the voltage, capacity, and size requirements for your battery. You'll also need to decide on the configuration, such as 10S2P or 10S4P, and choose the appropriate cells and connectors. Additionally, ensuring that the battery is shock-proof, weather-resistant, and within TSA limits for travel is crucial.
You can source parts from websites like Mboards.co, which offers a handy kit builder function. A Vruzend battery kit or a similar no-spot-weld battery kit can be useful if you're not experienced with spot welding. You may also need soldering equipment, copper wire, nickel strip tabs, and a Bluetooth module for programming.
Building your own battery can be more cost-effective than purchasing pre-made battery packs, as the battery packs are often the most expensive part of an electric skateboard. It also allows for customization and flexibility in terms of voltage, capacity, and size to suit your specific needs.
Yes, safety is a critical concern when working with batteries and electronics. It's important to avoid soldering 18650s as they can transfer excessive heat to the cells. Additionally, ensure that your connectors are capable of handling the current to avoid any potential issues while riding. Always follow best practices and seek advice from experienced builders when in doubt.
