Waterproofing batteries: the thread?

How bad is it if the phase bullets, sensor JST, or charge XT gets wet and short out?

Working on an enclosure adapter I can cast in epoxy so the connections and make them actually water proof but it would have an XT60, 2 sets of 1.5mm JSTs, and 6 5.5mm bullets in a row on the outside for everything to plug into

Hall sensors will be conformal coated and the charge port will have a 15A fuse inline

My old board had bullets integrated in the deck, so they were exposed to everything, spaced around 3 mm from each other. I’ve literally rode the board underwater and had no problems, but it was unsensored so I can’t comment on the JST

High-voltage unsensored motor windings are almost waterproof as-is, even without waterproofing. I’m guessing some extra-salty brine could make a small difference but probably not much. It’s mostly the low-voltage sensor assembly that gets messed up by moisture.

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In the case of doing holes on the enclosure I find this gland / grommet quite nice for the motor phase cables:

image

but I still don’t know what to do with the JST-XH balance connectors which are too big to fit. What do you guys suggest?

BTW, didn’t find information in the forum about routing the wires through the deck. Can this be done with any deck and how?

Run the wires through the enclosure and JB Weld the hole closed from both sides

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Ok thanks, I guess that would do it. Would hot glue also work (maybe a bit cheaper solution)?
In case I want to upgrade the motors would it be easy to remove the cables from the enclosure?

My personal suggestion is to not use sensors and to epoxy an MR60 connector into the enclosure that sticks out. Then it’s

  • waterproof
  • enclosure and motor are separable
  • nice looking
  • works great
  • no failures due to sensors
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