did not read every rant in the thread
How is the 3d printed enclosure holding up? I love the low profile of it.
Was it worth the work to make it look tidy? Might want to give it ago 
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Thanks man, definitely I will rough it up good
Actually it’s pretty simple to make this pattern, make a swept triangle cut and add torsion to it, pattern this a few times around the hole, do another one with the angle to the other side and also pattern that the same amount of times, and finally make a another pattern to propagate it to all 5 holes
Definitely worth, I must have between 2000 and 3000 km on it, has a few cracks that I super glued, others that couldn’t be fixed and a lot of scratches due to the board being so low. Overall it held up well, but regular ABS is not the material for it, need something stronger, more flexible and less subject to layer separation, ideally I would like to print it in one piece in something like nylon PA11, but way too expensive
I would also make some design changes, thicker walls, maybe change the screw location to eliminate the cracking problem, wouldn’t look as cool thought
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Thinking of printing it in two pieces, have access to a big printer, and making a mould out of the print, then vacuumbag some CF. Have a kit for the mouldprocess ready to go.
Would be fun if we could figure something out
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That would be cool, I bet if I had made the design more smooth in the corner, a layer of CF or even glass fiber would have made it last forever, but having the sharp design feature may not work
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All roughed up, sanded, cleaned and glued
Those titanium pulleys do look sexy, the motor shaft is a bit short but I think it’s good being 10 mm, plus set screws and retaining compound
Now to the battery pack, have to disassemble my ebike one
Now I’m thinking if I do a top mounted external pack that can also be used as range extender for the mountainboard or inside the enclosure. I still have an old 10S3P that I can use as the extender, one cell is badly corroded so I’m a bit afraid of messing with it, could make a 10S2P with it, but then I don’t have how to charge it
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Keeping the build theme, the battery is done, capable of massive 30 A discharge, so I had to take precautions and use a 10 AWG wire, but only outside, connecting the P groups is a 16 AWG, and off course a 30 A fuse
Also in one half the P groups are held to each other using double sided tape as a test, it isn’t strong but provides good isolation, the heat shrink holds it together
And after quite a while of chiseling and sanding all the silicone that held the old battery is removed so the double sided tape can stick to the wood, could have used silicone again but that takes too long to cure and I want to test ride tomorrow, still need to do a pice that will house the switch and the charge port on the top of the rear truck
The BMS is one that I bought at least 3 years ago and never used, hope of works, the battery is quite unbalanced since it was split in one 6S in my ebike and one 4S for a test board, so they are 3.83 V and 3.72 V respectively, I could have balanced manually but would take too much time
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First ride impressions
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Been a while since I wanted to do this, and unfortunately I’m out of dual lock Velcro, so tape will have to do for the initial test
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Quick as always, just a month latter, here we go, all in place with Dual Lock, need to make some 3D printed guides to run the wire in the side of the deck
Should have around 70 km of range, will see if I can test next weekend
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Some testing for the Iron Foot challenge, looks like the sweet spot is around 20 km/h, quite windy today so it might skewed the results a bit, and also the ESC measurements not being that reliable
I known can do 38 km with chill riding on this board, so maybe 65 to 70 km with the range extender
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I’m not sure, but I think I might need to print new pulleys
And I’m surprised it isn’t skipping and I ride with very lose
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Will you share the enclosure file? Love your work!
Sure
CaseStagedV1_part4.stl (4.3 MB)
CaseStagedV1.STL (14.5 MB)
CaseStagedV1_part1.stl (1.9 MB)
CaseStagedV1_part2.stl (2.5 MB)
CaseStagedV1_part3.stl (2.5 MB)
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CaseStagedV1One.STL (40.5 MB)
CaseStagedV1_part5.stl (2.2 MB)
CaseStagedV1_part6.stl (13.6 MB)
CaseStagedV1_part7.stl (1.0 MB)
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Thanks so much! 
1 Like