I had this radical idea to make enclosure out of aluminum u -channels and basically slide the battery inside and put a plate on top
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^This is a cross sectional veiw
the only thing is I feel it would not have any flex
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It wouldn’t have any flex but it sounds like it would be wildly strong. I think the issue is when something inflexible, but not that strong, is forced to flex and it just dies. Feel free to correct me but it seems like you’re just sacrificing weight and flex for ease of construction and strength
I’d also use something like a printed TPU bracket to hold the pack to the board, and work out a way to brace the “lid”
Any aluminum u channel should be able to handle the forces that deck puts on it I think, I would be more worried about what happens at each edge of the channel where the wooden deck suddenly goes from having a lot of support to having no support. I think a few decks have snapped the nose or tail that way.
Edit: maybe it would reduce the stress concentration to not have mounting bolts near the ends of the channels, or to put a layer of sift rubber between them and the deck
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Your not wrong. it would also make it slimmer. additionally
additionally if I make my battery like this ^ the "lid I plan on using will be to narrow, so the lip that will over hang the battery will make up for width.
My other idea is to buy ABS rods .5 x 1.5 x 36inches and make the frame out of that or maybe some 2x1wood (1.5x.75 actual size)
what do you think of this (DYNAFORM U Channel, ISOFR, 9/16 Leg, 1/8 In Th, 10 Ft - 4ATN1|870790 - Grainger) instead of the aluminum?
The 2inch width seems a bit overkill but its a decent material. Half as stiff as aluminum, nonconductive (good around batteries), but can’t really hold threads reliably (you would need to incorporate nuts if you’re gonna attach them with screws)
2 inches was the smallest size. but now I’m thinking maybe I should double stack my batterers
So, the new 6 series flips are fakes? They are really 4 series?
I chose the 6 BIG flipsky as I didnt even trust the 6 plus.
Anecdotally, my huge vesc has served admirably.
Yes, I would do that except consider putting 6 up front and 4 in the back, depending.
What enclosure do you have?
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oops, my bad.
which one would you suggest?
I recommend to
A) Use a deck that has an enclosure commercially available
or
I wouldn’t try anything else, but your results may vary.
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its too late for that
Maybe one day when I have the time. probably not in the next few months, probably at least 6 months.
With all due respect, the quality of your battery and enclosure are the two most important things.
Have you considered using a different deck that has an enclosure available?
Do you think that I’ve been in your exact position before?
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Another question, I have access to a cnc machine and was thinking about carving a thin rectangle out of the bottom of the board to make everything nice and flat, plus get a few more mm of clearance. would this be a bad idea?
I don’t know what to answer. I am assuming the answer is yes and you are trying to help me learn from your past mistake, but on the other hand it is very possible that you had the forethought not to make such a mistake.
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Yes, this is what we do around here 
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This depends a lot on the deck and your weight but many folks do it.
You can route out a lot if you cover the bottom in a layer of fiberglass afterward.
If it’s not much, you’re not heavy, and the deck is already super stiff, it might be okay. There are a lot of variables.
How much does the deck flex if you jump in the middle?
so I just took a slo-mo video of me jumping on the middle of my deck and it was surprising more flexible then I thought
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The battery isn’t going to appreciate that.