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My New Book “DIY Lithium Batteries” Is Now Available!

DIY lithium battery book

I’ve been teaching people to build custom DIY lithium batteries for years and have been building them myself for even longer. When I got started there was almost no info out there to help me learn how to build my own lithium batteries. Together with a few other like-minded individuals, I began a journey to learn what the heck I was doing. Thousands of batteries cells and many spot welders later, I’ve built countless batteries and collected a wealth of knowledge and research on the subject.

I began teaching others what I had learned. I wrote articles on the subject here on EbikeSchool.com and created a number of YouTube Videos on my Ebikeschool.com YouTube Channel to show people how to build their own lithium batteries.

All of that content was created free of charge and will always remain 100% free. I never want money to be an obstacle for anyone to learn something he or she is interested in.

At the same time, I also do this professionally and have to support myself as well. So I decided that in addition to the free content that I produce, I would write a book that goes much more in depth on all of the topics involved in building lithium batteries. The free videos and articles that I provide are a good start, but now I’ve written a much more professional guide in the form of my new book: DIY Lithium Batteries – How To Build Your Own Battery Packs.

 

The book is filled with everything I know about DIY lithium batteries and the skills needed to build your own lithium battery project. Here’s a list of the chapter breakdown:

Chapter 1: Introduction

Chapter 2: Form factors of lithium cells

Chapter 3: Types of lithium cells

Chapter 4: Sourcing lithium battery cells

Chapter 5: Cell ratings

Chapter 6: Combining cells to make battery packs

Chapter 7: Safety

Chapter 8: Battery Management Systems

Chapter 9: Construction methods

Chapter 10: Battery layout and design

Chapter 11: Making battery connections

Chapter 12: Sealing the battery

Chapter 13: Charging lithium batteries

Chapter 14: Increasing cycle life

Chapter 15: Disposing of old lithium batteries

Chapter 16: Example battery building projects

I put a ton of work into this book. I tried tracking my hours when I began but lost track of it when the number quickly grew into the hundreds. This was truly a labor of love for me and I’m very excited to share this book with all of my followers here on EbikeSchool.com.

DIY lithium battery book

 

“DIY Lithium Batteries” now available on Amazon!

 To thank you for supporting me and joining this community of ebike enthusiasts, I’ve set the initial price for the Kindle ebook version of the book at just $0.99 to allow you to pick up a copy for nearly free. (I had intended to offer a few download coupon but Amazon doesn’t make that easy). The paperback version of the book is also available for just $9.99 right now. Both of those prices will increase to their normal retail prices soon, but I’ll leave them at their low intro prices for a few more days as a thank you to my community here.

Also, you don’t need an actual Kindle e-reader device to take advantage of the cheaper Kindle ebook version. Amazon has a free app for all phones and operating systems to allow you to read Kindle ebooks on any device.

 

DIY lithium battery book

If you can’t afford it, then I totally understand and I recommend that you check out all of the free content that I have created. If you have benefited from my educational materials in the past and want to learn more as well as support my efforts, I’d love if you’d pick up a copy of my book and help make it possible for me to continue producing more educational content. Thank you guys for your support, I’m really grateful to have such a wonderful community around me!

Electric Bicycle Charging Station – Found One!

An electric bicycle charging station installed in my city? Am I seeing this right?!

electric bicycle charging station

I was walking my puppy (or as my wife calls her, our 3 year old, 65 lb dog) the other day when I saw something out of the corner of my eye that made me stop and backtrack to check it out. “That couldn’t be…” I thought to myself. Sure enough, it was an electric bicycle charging station!

This was really exciting, as I’ve never actually seen an ebike charging station like this in the flesh before. To be honest, I didn’t even realize they existed yet.

What’s so special about an electric bicycle charging station?

To put this in perspective, and in case anyone isn’t already aware, electric bicycles don’t charge like electric cars, where you need a special, high powered charging connector that is purpose built for electric vehicle connections. Ebikes charge from standard 110V or 220V wall outlets using a charger not unlike your laptop or cell phone charger. It simply steps down the voltage to the appropriate level for your battery and has a matching charging connector, like an RCA, XLR or other common electrical connector.

That means that technically any outlet is a charging station for an ebike. When I did my 800 kilometer (500 mile) Florida road trip last year, I would “guerrilla charge” by stopping at gas stations, convenience stores, restaurants or other businesses that had outdoor outlets. I’d always ask first, and most of the time the owner was happy to let me plug in for a while.

There are two main problem’s with guerrilla charging though: A) you’ve got to find a place with an outdoor outlet, which isn’t always easy (and reason A and a half is that you have to hope the owner agrees) and B) you have to always carry your charger. The first is never a guarantee and the second is something most people don’t want to do.

An electric bicycle charging station is basically just a larger, clunkier form for an ebike charger in that it plugs right into a standard 110V or 220V outlet, just like a normal ebike charger (or phone or laptop charger). It allows anyone with an ebike to stop on by, plug in for a while and then be on their way.

electric bicycle charging station

This charging station was plugged into a standard extension cord

The cool thing is that DIY electric bicycle charging stations would be relatively simple to produce and operate, and they could be installed in public places like parks, pedestrian walkways, bus stops, etc as part of a municipal project OR they could be installed by businesses as a way to entice customers or profit off a booming ebike market.

Is there enough demand for ebike charging stations?

I spotted this ebike charging station in Tel Aviv, which has one of the largest proportion of ebikes in a city outside of China. The ebike explosion in Tel Aviv has been huge, to the point that the tens of thousands of ebikes whipping around the streets and sidewalks have become a major safety concern, causing the city to begin enacting a series of laws to regulate ebikes and where they can ride (seriously… for example it’s now a law that if someone age 15 or younger is caught riding an ebike, the police officer can let the air out of his tires so he has to walk it home. I should write a whole article on the effect of mass ebike adoption on Tel Aviv).

Anyways, in a city like Tel Aviv with tens of thousands of ebikes riding around, these electric bicycle charging stations make a lot of sense. The ebike market is split with two main demographics making up the majority of users: teenagers and urban commuters. One the one hand, it’s quite common to see packs of teenagers (and unfortunately kids as young as 10) riding around the streets after school. Ebikes are the new ‘cool things’ and you’re not a cool kid until your parents have bought you an ebike. Imagine the high school freedom of your first car, but in middle school… and with an ebike. The other major group of ebikers are urban commuters: people getting to work and parents dropping off kids at school. Many times a week I see a parent with two kids on a 20″ folding ebike. I even saw four people on a single ebike once, but wasn’t fast enough with my camera. But I digress.

The point is that these groups are out there using their ebikes for long distances and are frequently running out of charge, evidenced by another common sight in Tel Aviv: people pedaling ebikes with dead batteries. Commuters have the luxury of keeping a spare charger at work, but the packs of teenagers that ride all afternoon and evening (until mom texts that dinner is ready) are stuck with the juice they’ve got in the tank, so to speak. Electric bicycle charging stations are perfect for both of these types of riders! Whether you forgot to charge your ebike at work or you just want to stay out riding for a bit longer on your cruise, stopping off for a quick 5A charge can buy you those extra electrons you need.

Tel aviv is obviously a special case though, as not every city has swarms of ebikes like we do. I’ve lived in a few different states in the US, and I’ve never seen more than a handful of ebikes there. Back in 2012 in Pittsburgh, I was one of maybe a dozen ebike riders in the city. In Southwest Florida I’ve seen perhaps one ebike per day. I’ve never lived on the west coast but I know that in California there is a growing number of ebikes, and I think that the west coast is probably the best place to start testing electric bicycle charging stations in the US. Any city that has a growing number of ebikes is surely in for an ebike boom in the next few years, and these ebike charging stations can be a great service for the community and potentially for business owners that install them.

One ebike charging station to rule them all

The most common types of ebikes here in Tel Aviv are the 36V, 250W EU-legal 20″ folding ebikes. The picture below shows the line of ebikes sold by the largest ebike importer in Israel, GreenBike.

The most common ebikes in Tel Aviv

The most common ebikes in Tel Aviv

What do you notice about most of these ebikes? They almost all use the same type of battery, often called a “Silverfish” style battery (the Chinese often name things after animals they resemble, though I can’t quite figure how they landed on this one). These batteries are very popular here because in a city known for bicycle theft, these batteries can be easily removed and carried by the rider using their built in handle.

They have a charging port on the side, usually RCA or XLR, but their discharge port at the bottom of the battery is apparently used by this charging station for charging the batteries via the small black platform at the bottom of the charging station. I’m not sure if that’s a factory component, or if this enterprising ebike shop owner hacked off the discharge platform from an old  ebike and mounted it onto the charging station to make charging easier for these types of bikes.

electric bicycle charging station

Charging connectors for many different batteries

This charging station offers charging rates of 5A, 8A and 10A which is possible for most batteries only by bypassing the BMS’s charging feature and charging directly through the discharge port. This allows higher power charging, but will not allow the BMS to cut off charging if a single cell group charges too high, at least on most BMS’s that I’m familiar with. This type of charging works, though doing it too often can be harmful to the battery. In theory though, this type of public fast charger is more likely to be used to put a bit of charge back into a nearly empty battery, and most people wouldn’t use a charger like this to completely top off their battery.

Another slightly more technical note: lithium batteries can be charged at higher rates when they are in a more depleted state, but are more likely to be damaged when fast charged at an almost full state. A proper fast charger will start out at a high current and slowly lower the current as the charge level increases.

I noticed that this charging station has a number of extra connectors draped over it, meaning you could charge nearly any type of battery, even if it isn’t the standard type used by most riders here. This is obviously quite easy to implement, as the electricity is the same regardless of the battery. All you need are a number of different charging connectors wired in parallel to accommodate different battery charging ports.

electric bicycle charging station

You’ll also notice from the pictures that this particular ebike charging station is a bit beaten up. I’d say “well loved”, but it looks more like it’s in need of some love. This is obviously going to be an issue for public charging stations, just like with any public infrastructure. Park benches are much stronger and beefier than any bench you’d put in your garden at home. This admittedly first attempt at a charging station has the right idea, but in a city with so many ebike users, a stronger design meant to withstand years of constant use is crucial to ensure the success of these charging stations.

Pay to charge?

The particular electric bicycle charger that I stumbled upon was coin operated, which brings up another issue all together: paying to charge. Ebike’s use very little electricity, and most ebikes with standard 350-500 Wh batteries can charge from empty to full for well less than the cost of a pack of gum. Considering the average US cost of electricity, an average ebike could charge fully for $0.06, which is about as near to free as you can get.

electric bicycle charging station

I’m not sure how much a commercial ebike charging station costs to install, but one could surely be built by a handy DIYer or Maker for a few hundred bucks. This begs the question of which is more valuable: profiting/recouping the investment of the ebike charging station, or providing a charging service in the hopes of bringing in more customers looking to patronize an establishment and get their sweet, sweet electron fix a the same time. That’s an issue that would be up to each business to decide for itself, but there is certainly a case to be made for both sides.

The future for ebike charging stations

This is only the first electric bicycle charging station that I’ve seen, but there are bound to be more in the future. Tel Aviv is a great test case to determine how often these charging stations get used and how much market demand there is for such charging stations. Pretty soon I think we’ll be seeing them popping up in various places along the west coast of the US and in some ebike-friendly cities in Europe. If you see any in your town, be sure to let me know in the comments below and send a picture while you’re at it. Until then, I’ll be on the lookout!

Save Money and Find Great Deals on China’s Shopping Holiday!

November 11th may just be another day to most of the world, but 11.11 is Singles Day in China, an online shopping holiday that positively dwarfs Cyber Monday, the US’s own online shopping holiday. There is debate as to the origin of the holiday, but the four 1’s in the date supposedly represent single people and the day is seen as both a chance to celebrate being single and to shop.

Regardless of the origin, one thing is for certain: it’s the single best day of the year to buy electric bicycle components, and pretty much anything else from China for that matter. I’ve only been participating for a couple years, but after finding sites like Aliexpress and Gearbest (and realizing they have the same stuff I buy locally, but direct from factory) I’ve been scoring an ever increasing hall of goodies each Novemeber. This Singles Day I’ve already created my shopping list in advance, and I thought I’d share with you guys some of the great ebike parts I’ve found that will be going on sale. Note: some of the links below are affiliate links. What that means is that if you shop via these links, EbikeSchool.com will receive a small percentage of the proceeds. This has no effect on you (the prices are the same low prices) but it is a huge help to keep this site up and running, and most importantly free!

BBS01, BBS02 and BBSHD

Mid-drives are becoming king of the road on electric bicycles due in large part to their increasing ease of installation, stealthy design and low weight. The Bafang 8fun BBS01 (250W-350W), BBS02 (500W-750W) and BBSHD (1,000W) mid-drive kits are probably the best well known. If you’re in the USA, Luna Cycle usually has the best price on the two larger versions of the kits, but on Singles Day even Luna can’t beat the holiday prices.

Complete BBSHD kit for just $561 with free shipping!

Complete BBSHD kit for just $561 with free shipping!

The largest Bafang mid-drive shop on Aliexpress is having some amazing sales, including the BBSHD for $561, the BBS02 for $365 and the BBS01 for only $297! And all of those prices include free shipping! I’ve used this vendor before and been more than satisfied – good parts, good communication and great prices. In fact, I’d recommend checking out their online store, where pretty much everything is on sale for Singles Day. They’ve got tons of parts and accessories for Bafang 8fun kits, including replacement displays for as low as $30.

48V 10.4AH shark pack for just $305 shipped

48V 10.4AH shark pack for just $305 shipped

The same vendor also has battery packs for great prices, including a Hailong (shark) 48V 10.4AH pack for just $305 or another Hailong 48V 14AH pack for $424 which uses the high quality Sanyo GA cells. Any other day and their prices wouldn’t be much better than Luna Cycle’s, at which point I’d recommend buying from Luna, but on Singles Day, you can’t beat these prices.

Same pack but at 48V 14AH with Sanyo cells for $440

Same pack but at 48V 14AH with Sanyo cells for $424

Now, even though they have good reviews, I don’t have much experience using the batteries from this vendor so I can’t personally vouch for them. But I can personally vouch for the next vendor from whom I’ve bought at least a dozen batteries.

High quality and inexpensive electric bicycle batteries

Generally speaking I recommend being wary of buying an ebike battery from overseas. If you don’t know the vendor or the quality of their work, it can really be a toss of the dice. But this particular vendor has proven themselves to be a high quality source for great batteries with genuine, top of the line battery cells and fantastic battery pack production. I’d still love if you supported my own battery project now on Kickstarter, but if you want your battery already assembled, look no further than my favorite AliExpress battery vendor.

Here is just a sampling of the deals they are having for Singles Day. You can get the same Hailong (shark pack) battery from above, but at 48V 11.6AH for just $305!  And that pack is using Samsung cells (which I assume means 29E cells), not some cheap knock-off cell.

Same shark pack at 48V 11.6AH for $305

Same shark pack at 48V 11.6AH for $305

And check out this deal: a 52V 20AH triangle pack using genuine Panasonic 18650pf cells with bag and charger for just $545. This pack costs around $700 including charger and shipping at Luna. Any other day of the year, it would only be about $50 cheaper to get it from this vendor on Aliexpress, at which point it’s probably worth it to go with Luna for their good warranty and support, but today you can save over $150 by getting it from Aliexpress. For me, that’s definitely worth it, but you’ll have to make that call yourself.

48V 20AH triangle battery for $545

48V 20AH triangle battery for $545

Want to upgrade your Sondors ebike? They’ve got a Sondors-ready 48V 20AH triangle battery for just $355. You can get the same 48V 20AH battery in a rectangle instead of a triangle for just $333. These two appear to use generic cells, but hey, it’s for a Sondors ebike, so… yea…

Anyways, they’ve got tons of good ebike battery and charger deals for Singles Day, check out the rest of their sales here.

Spot Welders

If you’ve been considering getting a spot welder to build your own batteries (especially if you read my article on battery building) then you’ve got some good spot welder sales coming. The 787A spot welder will be down to $120 while the 709A spot welder with hand probes will be down to $203. Prices fluctuate a lot on these welders but both are pretty good deals.

787A spot welder for $120

787A spot welder for $120

Electric bicycle accessories

Some of my favorite accessories are also on sale for Singles Day. I absolutely love this slim little bicycle multitool for just $7.

$7 bicycle multitool

$7 bicycle multitool

It’s also a great time to stock up on connectors like XT-60’s for about 50 cents per pair, or 45A Anderson PowerPole’s for just over $1 per pair.

XT-60 connectors for 50 cents/pair

XT-60 connectors for 50 cents/pair

Do you have an emergency roadside pump? It’d be a shame to be stuck pushing your bike home when you could have stashed a $3 pump somewhere on your bike.

And what about lights? This insanely small but bright 960 lumen headlight with over 500 positive reviews is normally $80 but on sale for $23 this Singles Day!

960 lumen headlight for $23

960 lumen headlight for $23

If you’d prefer something a little more ‘normal’ powered, this 12V-80V head light has a built in DC-DC converter so it can run straight off your battery. And 18W is pretty powerful for just $7.

For $7 you can run this headlight straight off your ebike battery

For $7 you can run this headlight straight off your ebike battery

And while you’re add it, consider adding some flexible waterproof light strips to your bike. These are just $0.70 each for 1 meter long strips. I added white lights to the front of my bike and red lights to the rear for a really well lit night riding setup. You can read my how-to article on adding these types of 12V lights to your bike without a DC-DC converter here.

Just $0.70 each for these flexible LED strips

Just $0.70 each for these 1 meter flexible LED strips

Depending on how obnoxious you want your bike to look, you can pick up one of these multi-colored wheel light designs for less than $5.

screen-shot-2016-11-10-at-12-47-51-pm

Alright, this seat is ridiculous, but part of me really wants to try it. I don’t know if I’m going to pull the trigger on this or not, but for some reason I still have it sitting in my cart. It just looks like it could be super comfy, especially with the extra springiness of the frame. Or it could be terrible. Though that weird hook in the back would make a great handle for lifting my ebike or for wrapping a chain lock around. If anyone has this seat, please let me know before the end of the day if you like it!

For $30, I am not sure if I want to try this weird but awesome seat.

For $30, I am not sure if I want to try this weird but awesome seat.

Cheap electric bicycles conversion kit

Entire ebike conversion kit for $384

Entire ebike conversion kit for $384

Alright, we’ve all got that friend, coworker or family member that heard about how we built our own ebike and has been bugging us to make one for them too. Most people balk at the price of ebike conversion kits, but if all they need is a simple, low power kit then this may be good for them. It’s a 36V 350W kit with your standard inexpensive 8.8AH battery, but it’s only $384! And that’s for everything: the motor, battery, controller, controller case, brake levers, throttle, display, wiring, PAS unit, headlight… everything! This is not a powerful or top of the line kit, but if you’ve got a bike that you want electrified for less than $400, this is the way to do it.

Even complete electric bicycles?!

Aluminum fat bike for $1,160

Hilariously, you can even get complete ebikes on sale for Singles Day. This 36V 350W fat bike is on sale for $1,160 with free shipping straight to your door. The spec’s aren’t killer, but it’s still a better price than you’d ever find locally for an aluminum frame electric fat bike. Don’t expect to be climbing any mountains on it, but messing around on the beach or in snow should still be pretty fun. Plus it’s already better than a Sondors.

48V folding ebike for $945

48V folding ebike for $945

The same vendor also has a cute little 20″ folding 48V ebike for $945. Most of us could build our own version of this ebike for a little bit less, but that internal battery is a pretty nice feature that is difficult to recreate yourself. And for someone that doesn’t feel comfortable going the DIY route, this is a relatively inexpensive way to get yourself a peppy little folding ebike, considering that comparably spec’d ebikes in the USA retail for about twice as much.

Non-ebike related things

I usually get a pile of ebike parts on Singles Day, but there are some other amazing deals out there too. Last year I got my wife an iLife robotic vacuum cleaner – basically a Roomba knock-off but at about 80% off the price of a Roomba. With a fur-factory of a dog at home, nothing has taught me the truth of “happy wife, happy life” more than this single purchase.

Roomba-style robotic vacuum for $141

Roomba-style robotic vacuum for $141

Last year we got my wife a Microsoft Surface tablet and I’ve been “borrowing” it more and more so I decided to finally get myself a tablet. After a bunch of research, I’ve settled on the Chuwi 10.1″ tablet. It’s got basically the same functionality but is only $139 on Singles Day. With 64Gb of storage, 4Gb of RAM and a quad core intel processor, plus Windows 10 and Android operating systems, it’s more than I need for my casual use (let’s be honest, browsing Facebook and Endless-Sphere or writing Ebikeschool.com articles).

Chuwi 10.1" tablet laptop for $139

Chuwi 10.1″ tablet laptop for $139

There are also tons of great deals on similar tablets and smartphones, so if you’ve been on the fence about some new electronics and don’t need to pay hundreds of dollars for a brand name, consider a Chinese version like Chuwi or Huawei.

So that’s the list of the main things I’m looking at this Singles Day. But there are literally hundreds of thousands of items on sale, with way more ebike related things than I could list here. I recommend checking out this page on Aliexpress which lists all the sale items by category, and jumping into the cycling category under sports and outdoors. Or check anything you’d like. There are crazy deals on everything from hiking back packs to blenders… seriously.

Good luck and even if you aren’t single, Happy Singles Day!

 

Helpful links

Here a few topics and sources that you might find helpful:
How to build a battery
Inexpensive ebike batteries
Endless Sphere ebike forums
Cheapest 8fun mid-drive source
Ebike School Youtube Channel

My Current Favorite Battery Source

My favorite source for batteries right now is Battery Hookup. They’ve also generously offered all of my readers a 5% discount if you use the discount code EBIKE.

This site is 100% free, so how do I support it?

All the help and knowledge I've provided here on EbikeSchool.com is 100% free If you want to support this site and help me keep it free, consider checking out my ebook and video course on building ebikes.

Ebikeschool.com has a lot of great info, but I've spent countless hours putting even more info, examples, how to's, reviews, maintenance steps and buying guides into my book and video course. They are some of the most fact-dense and info-rich ebike resources available today. So check them out to see if they can help you with your own ebike!

Learn more here.

If you want to learn more in-depth about building your own lithium battery, you'll want to check out my book "DIY Lithium Batteries: How To Build Your Own Battery Packs" which is an Amazon #1 Bestseller in multiple categories!
You can get it here on Amazon.

And if you don't want to purchase my book (or you already have a lot of ebike knowledge), you can still support this site by simply clicking on this link before you shop on Aliexpress. Basically, that's an affiliate link that shows Aliexpress that you came to them via my site. It doesn't effect you at all, but if you make a purchase, this site will get a small percentage of the profit that Aliexpress makes. It's a simple way to help support this site so I can pay the hosting and keep providing more free info (and to keep this site free of annoying ads). I have some of those affiliate links on a limited number of articles on my site. When I personally buy and test products that I find to be a combination of great quality and great prices, like these batteries, for example, I like to share them through those affiliate links. Again, it costs you nothing, but it allows me to keep cranking out more info and content for you guys!

Thanks for understanding!










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