Great! And are the cables/adapters okay to power the motor with this battery ?
Full Power to Lightweight - Bosch 800Wh replaced with 400WH compact
- Thread starter neiloxford
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Great! And are the cables/adapters okay to power the motor with this battery ?
neiloxford
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- #62
I have not tested that - I will test it now
neiloxford
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- #63
I just tested the 400wh battery with the connectors that I mentioned in this thread, and the bike powers on and off, and displays the battery charge.
I can't test ride it yet as I have not finished the mounts.
The 400wh battery has been used with the Crestline with a Bosch Gen 5
I can't test ride it yet as I have not finished the mounts.
The 400wh battery has been used with the Crestline with a Bosch Gen 5
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Nice
!Apparently, several manufacturers make bikes with a Gen5 motor and a 400 Wh battery without any power limitation. The issue is more about adapting the CompactTube battery to a bike equipped with a PowerTube battery
neiloxford
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- #66
@ Davzell - are you able to use a 600wh battery with your bike - can you get a smaller mount ? The trek rail can use a 600wh battery, so I was going to make the top mount smaller by designing it for the holes of the 600wh battery, or does your top mount accept both 600wh and 800wh batteries ? To give you context, this is the top base mount, with the holes roughly in place for the 600wh battery.
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yes my bike support 600 and 800wh battery. There is two different support
there is
fixed on the the cover
the connector to battery between Mondraker and treck seems to be similar
"The top of the battery does not attach the same way between Mondraker and Trek, but if the battery with the 3D part has the same length and the same holes as the 800 Wh battery, it will fit easily.
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neiloxford
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4th part completed.
It is too dark to safely test it so I will have to wait until tomorrow....
I have ordered a new battery cover which hopefully arrives later in the week, so once that arrives I can position the holes in the lower base, and it will be finished.
It is too dark to safely test it so I will have to wait until tomorrow....
I have ordered a new battery cover which hopefully arrives later in the week, so once that arrives I can position the holes in the lower base, and it will be finished.
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neiloxford
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- #69
I plan to use this company and this filament to make my final finished version.
www.3dmitech.co.uk
If anyone knows a better company / a better filament, please let me know.
If anybody can advise on the infill percentage, please let me know - thinking 30%
Nylon PA12-CF | Carbon Fiber Filament | High-Strength | Heat-Resistant
Explore PA12-CF Nylon 12 Carbon Fiber—lightweight, high-strength filament with excellent heat resistance and stiffness. Ideal for aerospace, automotiv
www.3dmitech.co.uk
If anyone knows a better company / a better filament, please let me know.
If anybody can advise on the infill percentage, please let me know - thinking 30%
Do you have this company do it so that the parts are stronger?I plan to use this company and this filament to make my final finished version.
Nylon PA12-CF | Carbon Fiber Filament | High-Strength | Heat-Resistant
Explore PA12-CF Nylon 12 Carbon Fiber—lightweight, high-strength filament with excellent heat resistance and stiffness. Ideal for aerospace, automotiv
If anyone knows a better company / a better filament, please let me know.
If anybody can advise on the infill percentage, please let me know - thinking 30%
neiloxford
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- #71
The bosch parts are made from PA6-GF35, which is very strong and has heat distortion around 200 C
PLA has heat distortion at 50 to 60C - so a hot day in the sun.
PETG is better at 70 to 80C
ASA is better at 85 to 105C, but I am worried that this might not be high enough - it is unclear how hot it gets near the motor due to a combination of the sun & the motor.
So thinking I should print in PA12-CF which has a higher temperature, and happens to be very strong, so looking at using a company.
This company uses PA12-CF35 which has heat distortion at 177C
neiloxford
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- #72
Test ride completed - battery works, and it fits well with no movement.
I need to wait for the battery cover to arrive and I can then accurately line up the holes on the lower base.
At the moment the boxes do not screw together - I will let people add this feature if they want it. I am planning to glue mine together as I see this as a permanent solution.
I will share the designs when finalised, so that people can print themselves, improve the design, adjust to their bike frames, etc.
I need to find out how to share the designs so that I am not responsible for injury / damage to bikes / etc.- If anybody know how I can do this, please let me know.
An example of a tweak for the Trek top bracket is the notch in the base of this part, and the shaping of the corners.
I need to wait for the battery cover to arrive and I can then accurately line up the holes on the lower base.
At the moment the boxes do not screw together - I will let people add this feature if they want it. I am planning to glue mine together as I see this as a permanent solution.
I will share the designs when finalised, so that people can print themselves, improve the design, adjust to their bike frames, etc.
I need to find out how to share the designs so that I am not responsible for injury / damage to bikes / etc.- If anybody know how I can do this, please let me know.
An example of a tweak for the Trek top bracket is the notch in the base of this part, and the shaping of the corners.
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nice try !
check cults3d, thingiverse or Printables for share plan, maybe there is protection in there Terms, Privacy, and Rights.
I see this on shared plan.
Add disclaimer to your sharing like this "
Disclaimer
This 3D model file is provided “as is,” without any warranties, express or implied, including but not limited to fitness for a particular purpose, safety, durability, or compliance with any technical or legal standards.
By downloading, printing, or using this file, you acknowledge and agree that:
- You are solely responsible for verifying the suitability, safety, and performance of any printed object.
- The creator of this file shall not be held liable for any damages, injuries, losses, or issues arising from the use, misuse, modification, or distribution of this file or any object produced from it.
- This file is shared strictly for personal, educational, or experimental use, and not for critical, structural, medical, food-contact, or safety-related applications.
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SS state batteries with 500w/ kg are hitting production right now even in cars, which is the most expensive application for them. We're currently sitting at about half that density.
Let's all hope that we can all have a huge watt battery in the space and weight of the current 400-600w batteries and it's fully retrofittable very soon.
Let's all hope that we can all have a huge watt battery in the space and weight of the current 400-600w batteries and it's fully retrofittable very soon.
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Bogdan_CH
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When solid state will reach the bike marker for sure they won't make it backwards compatible, they will make you buy the "next" gen bikes as well
neiloxford
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- #76
I have signed up to thingiverse, and now need to wait 24 hours until I can publish. I will share the top mount first, as that is finished.
Fazua made an upgraded battery backwards compatible. It's just a battery afterall.
Since Bosch is struggling a bit because of DJI, I think it wouldn’t be impossible for them to try to catch up a little and avoid the backlash that came with the launch of the Gen5 motor. They could release a retro-compatible, lighter battery for the Gen5 while waiting for Gen6.
That would still mean paying €1000 to buy it, which isn’t ideal.
Bogdan_CH
Active member
I know. My brother bought it
it's around 10% heavier for 10% more battery. Nothing ground breaking but it's good it fits in the same space I don't find it struggling personally. The techy gimmicks are cool on the DJI but to me Bosch is still the top player :
- it doesn't rattle
- it's still one of the most reliable
- the fact that I can switch between 600wh to 800wh in seconds it's good.
Now back to SS, I haven't studied them too much but :
- if the benefit is to make them lighter in the same form factor then yes, retrofitting one would be nice and could be an option.
- if they allow a smaller form factor for sure they will slim those batteries down, pass the new designs to bike brands and for sure they will want new money coming in with new bikes as we all have to get the latest and greatest
that's just how economy works.First I am hearing of Bosch "struggling" and receiving "backlash" since the release of the gen 5. If anything I would say it has gotten one of the best receptions of any motor and nearly all of the large bike manufactures are using them for their 2026 bikes. I'm not sure I would consider that struggling.
I don't own a Bosch bike btw.
Je sais. Mon frère l'a acheté,
Personnellement, je ne trouve pas cela problématique. Les gadgets techniques du DJI sont sympas, mais pour moi, Bosch reste le meilleur.
- ça ne fait pas de bruit
- c'est toujours l'un des plus fiables
- le fait que je puisse passer de 600wh à 800wh en quelques secondes c'est bien.
Revenons maintenant aux SS, je ne les ai pas trop étudiés mais :
- si l'avantage est de les rendre plus légers dans le même format, alors oui, en installer un ultérieurement serait bien et pourrait être une option.
- s'ils autorisent un facteur de forme plus petit, ils réduiront certainement ces batteries, transmettront les nouveaux modèles aux marques de vélos et voudront certainement que de nouveaux fonds arrivent avec de nouveaux vélos, car nous devons tous obtenir les derniers et les meilleurs,
Whether Bosch is better than DJI in terms of overall motor performance, I don’t know, as I haven’t tested DJI. However, when it comes to weight and motor/battery size, Bosch is ahead—especially with their new motor expected to be available on bikes by early 2026, which promises even more weight savings. This is where I think Bosch could really make a difference by releasing batteries compatible with the Powertube 600/800 socket but lighter. I believe that people interested in a lighter bike might prefer switching to a new battery rather than investing in a brand-new €10k bike.I know. My brother bought it
I don't find it struggling personally. The techy gimmicks are cool on the DJI but to me Bosch is still the top player :
- it doesn't rattle
- it's still one of the most reliable
- the fact that I can switch between 600wh to 800wh in seconds it's good.
Now back to SS, I haven't studied them too much but :
- if the benefit is to make them lighter in the same form factor then yes, retrofitting one would be nice and could be an option.
- if they allow a smaller form factor for sure they will slim those batteries down, pass the new designs to bike brands and for sure they will want new money coming in with new bikes as we all have to get the latest and greatest
For the moment, no, because many of the new bikes are Gen5. But maybe with the 2026 generation, that will be less the case—or at least more manufacturers will release models with a DJI motor alongside those with Bosch motors, just like it was with Shimano motors, which are now disappearing.
This would reduce Bosch’s market share. Bosch needs to react to DJI, but we can see that releasing a new motor and battery that aren’t backward compatible has caused an ‘uproar’ for some. Releasing only a battery that is backward compatible seems like a good move to me. But maybe that’s just because I hope they’ll do it for my own bike
We are already seeing model year 26 bikes. I can see most gen 5 equipped designs lasting 2/3 more seasons as the bike manufactures want to get the most from their investments in tooling and R&D. They are unlikely to switch to another motor provider before their current offerings run their course. The Shimano comparison doesn't really fly as the gen 5 system is still up to date. For the vast majority of people 100nm/750w is fine and will still be fine in 2027/28.For the moment, no, because many of the new bikes are Gen5. But maybe with the 2026 generation, that will be less the case—or at least more manufacturers will release models with a DJI motor alongside those with Bosch motors, just like it was with Shimano motors, which are now disappearing.
This would reduce Bosch’s market share. Bosch needs to react to DJI, but we can see that releasing a new motor and battery that aren’t backward compatible has caused an ‘uproar’ for some. Releasing only a battery that is backward compatible seems like a good move to me. But maybe that’s just because I hope they’ll do it for my own bike
do you avec picture of the inside "box" with cable and adapter ? What size do you have buy for Bosch cable BCH3901 ?
So I’m talking about the 2026 generation models coming out in 2026. Not the ones we’re already seeing now.
For example, with Mondraker, I have a 2026 model of the Crafty Gen5 that’s being released as early as June. That one will stay with Bosch because there’s currently a partnership, and like you said, they’re not going to completely change it after only 6 months on the market.
However, they will be releasing another model in 2026, very likely a Mondrakerer, which will be equipped with the new DJI motor (not available yet) .
It’s 3 kg lighter than the Mondraker Crafty while still being a full-power e-bike, with a 120 Nm motor and an 800 Wh battery.
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Bogdan_CH
Active member
Just curious where this data is coming from. Do you have a refference for it ?
As well, the weight difference between a Bosch CX or CX race + a 800wh battery to a DJI + the 800 wh is 500 grams . The other 2.5 kg's should come from elsewhere. Non removable battery, up to a maximum 500 grams, which is still a bit strech but besides that, lighter parts mostly.
Indeed, the current motor is barely lighter than the Bosch Gen5.
The next DJI motor and the battery will apparently be even lighter.
I think the shape of the motor/battery also allows for different frame designs, which helps save more weight there.
That’s what I keep telling people who praise DJI for the weight savings on the Amflow bike: the motor saves a little, but it’s mainly the frame and components that make the overall weight lower.
As for the information, it comes from reliable sources.
Nothing on web for the moment
neiloxford
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- #88
Thanks! So, were the adapters glued on then? Or how are they fixed?
neiloxford
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P.S I am now looking at printing with PA12-GF by SLS using this company:
SGD | Expert SLS Nylon 3D Printing Service - Fast Turnaround
Much more expensive - around £75 to print a set of mounts, but the strengh in all planes seems sensible.
Chatgbt compares the two:
SGD | Expert SLS Nylon 3D Printing Service - Fast Turnaround
Much more expensive - around £75 to print a set of mounts, but the strengh in all planes seems sensible.
Chatgbt compares the two:
Choose PA12-GF (SLS) if:
- You want consistent strength in all directions
- The mount is structural or safety-critical
- You need tight dimensional tolerances
- You're okay with heavier but more durable parts
- You plan to do batch production or use a service bureau
Choose PA12-CF (FDM) if:
- You need a lightweight mount
- Strength mostly needed in X/Y plane (layer direction)
- You're building custom or one-off parts
- You have access to a high-end FDM printer (like Markforged, Raise3D, or Prusa)
- You want faster turnaround at lower cost
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