Full Power to Lightweight - Bosch 800Wh replaced with 400WH compact
- Thread starter neiloxford
- Start date
Yes, I think the setup could work on bikes with the sliding battery system like Crestline, but for the others it seems complicated. I contacted someone who makes parts with 3D printing, and he could make the parts adapted to the CompactTube 400, but the price would be high."
It's a pity Bosch released a 540 battery that's just as heavy as the 600; a 400 PowerTube weighing 2 kg would be great.
Plummet
Flash Git
Yeah plates are from Crestline. The plug is on a wire and plus in once the battery is installed.
Plummet
Flash Git
No addtional cable needed. I have a crestline.
Plummet
Flash Git
Yeah that would be a challenge.
The Pole has a similar set up. It was fast battery removal but limited adjustment for when the battery terminals get a nit worn and loose. I had battery connection issues on the Pole and it was always that damn fixed connector
neiloxford
Active member
- Thread starter
- #36
I would be interested in buying 3D parts, but it would be helpful to understand what a high price is ?
Thinking it would need some additional parts such as these...
Bosch BCH3901 Charging Socket Cable
Keeping eBike components up to date is key to your safety. Buy your Bosch BCH3901 Charging Socket Cable from All Terrain Cycles today.
www.allterraincycles.co.uk
Bosch CompactTube 400 Wh screw-on plate | horizontal/vertical
Bosch CompactTube 400 Wh screw-on plate ► horizontal/vertical | removable/fixed | lock side/contact side ► Buy now!
www.ebike24.com
It would probably take several dozen, or even up to a hundred, hours of R&D, so the hourly bill would quickly add up. The person would also need the right bike, the compact tube battery… a lot of things, really.I would be interested in buying 3D parts, but it would be helpful to understand what a high price is ?
Thinking it would need some additional parts such as these...
Bosch BCH3901 Charging Socket Cable
Keeping eBike components up to date is key to your safety. Buy your Bosch BCH3901 Charging Socket Cable from All Terrain Cycles today.
Bosch CompactTube 400 Wh screw-on plate | horizontal/vertical
Bosch CompactTube 400 Wh screw-on plate ► horizontal/vertical | removable/fixed | lock side/contact side ► Buy now!
Bosch BCH3901 Charging Socket Cable
Keeping eBike components up to date is key to your safety. Buy your Bosch BCH3901 Charging Socket Cable from All Terrain Cycles today.
Bosch CompactTube 400 Wh screw-on plate | horizontal/vertical
Bosch CompactTube 400 Wh screw-on plate ► horizontal/vertical | removable/fixed | lock side/contact side ► Buy now!
The battery has a female socket, and the fixed connector where the battery plugs in (at least on my bike) is a male socket. So this cable alone won’t work.
However, maybe by adding this adapter, there could be a way to make it work.
But honestly, I feel like it’s a bit too much of a ‘DIY hack’ just to get to the result
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neiloxford
Active member
- Thread starter
- #39
It is possible to see they have done a DIY hack of sorts...2 photos with 400wh, and one with the 600wh which fits lower in the frame.
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I asked Sporttechnik.de if it’s possible to swap a CompactTube and a PowerTube battery on her bike. It’s not possible because they use different holders.
neiloxford
Active member
- Thread starter
- #42
I have purchased a battery and a cheap 3D printer - I will see if I can produce a couple of universal mounts.
Nice try
! What bike do you have ?neiloxford
Active member
- Thread starter
- #44
I have a Trek Rail Gen 5. which uses these attachments with the 600/800wh.
Hoping to create a power mount which is about 6cm long, and then the other end about 1cm.
Hoping to create a power mount which is about 6cm long, and then the other end about 1cm.
Looking at your bike’s layout, it seems to be made the same way as mine. I think we’ll have an issue with the height of the battery connector. On the PowerTube 800/600, the connector is located at the very top of the battery’s front face. On the CompactTube 400, if we orient the battery the same way, the connector will be at the bottom. As a result, we can’t make a direct connection to the port on the bike.
neiloxford
Active member
- Thread starter
- #46
I am expecting to make a mount which attaches to the bosch 600/800 power mount in the bike, which I believe to be standard due to the 600/800 battery, and then connects to the 400 battery, at an offset. I am new to 3D design and printing, so I expect some trial and error. I am going to make it in PLA filament first, and then ASA filament when I am happy with the design.
This is a first attempt of the design after a couple of hours. I will need to measure everything, and improve the design, but gives you some idea of my current approach. If I can get a functional design I will be happy, and perhaps someone else will be able to optimize it. The BAD 2 adaptor will go into the lid, and the BCH3901 will go in the box.
This is a first attempt of the design after a couple of hours. I will need to measure everything, and improve the design, but gives you some idea of my current approach. If I can get a functional design I will be happy, and perhaps someone else will be able to optimize it. The BAD 2 adaptor will go into the lid, and the BCH3901 will go in the box.
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Ok, I also think that the solution for the sockets that don’t line up at the same height is the BAD 2 adaptor and the BCH3901. Can’t wait to see if it already works with just the battery + adaptor. And then the 3D mounts
neiloxford
Active member
- Thread starter
- #48
3 hours of tweaking and printing has got me to this concept box.
When the battery arrives next week I will be able to improve the design.
When the battery arrives next week I will be able to improve the design.
Nice !
And how are you going to fix the box in the battery compartment?
Plummet
Flash Git
Probably an easier way is to make a hollow box spacer. Wire the plug/socket so you can plug it in separately. Then you remove the tolerance to get the plug exactly right and can focus securing the battery with the 3d printed parts.
ValActionT 750
Member
If one was a snarky arse, they’d say lose 2kg of body weight.
neiloxford
Active member
- Thread starter
- #52
neiloxford
Active member
- Thread starter
- #53
Thinking I will make the box larger, screw it on to the 400wh battery, and make it so the total length is the same as the 800 battery. Then attach the trek battery cover so I can easily swap between the 400 and 800 battery.
neiloxford
Active member
- Thread starter
- #54
That would be easier, and lighter - I might end up with that solution
neiloxford
Active member
- Thread starter
- #55
A productive Saturday - just need the 400wh battery to arrive and I can align the holes on the lid.
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neiloxford
Active member
- Thread starter
- #56
Almost completed the design stage - I just need the 400wh battery, and I can finalise the placement of the bolt holes. I have just ordered some bolts, so the design should be ready to test next week.
I am somewhat shocked that the 2025 mondraker crafty has the battery connection and charging port placed beneath the battery. I'd have the charging port and connector at the top. Seems like pretty low hanging fruit for lowering the cg of the bike.
On that subject, I'd like to have a 400wh battery in the outer diameter of the 800wh, so that the form factor might be shorter, and thereby lower the cg.
I'm following this thread with great interest !
On that subject, I'd like to have a 400wh battery in the outer diameter of the 800wh, so that the form factor might be shorter, and thereby lower the cg.
I'm following this thread with great interest !
neiloxford
Active member
- Thread starter
- #58
I received the battery from Alltricks - not a great experience - I have had to pay VAT twice, despite the banner on their website. Annoyingly the delay has meant no progress this week, and I am unlikely to be able to work on it until next weekend which is annoying.
hello, some news ?
neiloxford
Active member
- Thread starter
- #60
3 out of 4 parts completed
The remaining part is the upper base mount - making it the same as the 600/800wh battery.
I also need to add some holes to the lower base mount to attach the Trek battery cover - these will match the 600/800wh battery, so will work for other brands.
The remaining part is the upper base mount - making it the same as the 600/800wh battery.
I also need to add some holes to the lower base mount to attach the Trek battery cover - these will match the 600/800wh battery, so will work for other brands.
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