DIY electric longboards are a ton of fun to build and ride (we’ve featured several builds before). Most boards have batteries strapped to the bottom of a rigid board, or they have battery packs near each truck so the board can still flex. Instead of going with either of these designs, [Ben] created a custom battery pack design that’s able to flex with the board.
[Ben]’s pack is made up of A123 26650 cells nestled in his custom-fabricated enclosure. [Ben] designed his pack in CAD and used a CNC machine to create a foam mold. He used the mold to do a fiberglass layup, vacuum-bagged it, and left it to cure. Since the fiberglass bonded really well to the foam, [Ben] used acetone to dissolve the foam while leaving his fiberglass layup intact.
[Ben]’s pack fits 18 cells which he soldered together with some flexible copper grounding wire. The top side of the enclosure is covered with a layer of insulating rubber, and the rim is covered with a soft foam to form a gasket against the board. As you can see, the pack bends really well with the board, and it doesn’t look like [Ben] has had any issues with his design so far. Check out [Ben]’s blog for more info and for more details on the overall design of his board.