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How do I build a cylindrical battery pack from common Li-ion cells?

I would like to build a replacement battery pack for a Faraday eBike. How should I best do this?

This question was opened under the category, manufacturer:VanMoof, because “Faraday” was not listed in this forum’s drop-down menu, and there is nothing closer to a Faraday bike than a VanMoof eBike; both manufacturers locate their narrow batteries *inside* the downtube of the bike frame.

Every model of Faraday uses the same battery pack, and probably identical electronics, too.

A Faraday dealer confirmed to me that Faraday uses the same category of Li-ion cells as most other eBikes. The cells are cheap, but the assembled battery pack costs $600 from Faraday.

Pictures and video of the battery pack can be seen here: https://support.faradaybikes.com/hc/en-u...

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Did you successfully replace your Faraday battery pack? I am hoping to do the same thing with one I just purchased used.

da

@Brent Wilkes No, I was hoping to learn about this topic before I needed to actually do the work. So far, my original pack is still good.

Two years ago, I did read something vague in the Faraday documentation about a large number of sensors which monitor the battery pack. That would not necessarily stop me from trying to make my own pack, but it would encourage me to carefully dissect to the original to see if I could use any components in my own build.

I would be very interested to learn about your own decisions. I have not recently checked in to see if battery packs are still available at what remains of the Faraday company.

da

On somewhat unrelated topics:

I did recently discover that finding a replacement for my bottom bracket sensor is not trivial. I needed to do this for a friend's Faraday, and I succeeded after many tries and Deutsche Marks. Soldering was also required, because the sensor is no longer sold with a Julet connector (green, 5-pin). Do not attempt to disassemble a Julet connector; they seem like a relatively good design, but they are not serviceable.

If you ever remove your BB sensor, carefully follow Faraday's instruction set after identifying the sensor model. A mis-applied wrench can easily destroy the Julet connector

Motor controllers and mode selectors were still available from Faraday, and they seem to be replaced more frequently than other parts. If those 2 parts are still available, and you plan to keep using the the Faraday electronics for a long while, then I suggest investing in spares.

Would you like me to post further advice about those 2 components? I have reached the character limit for this msg.

da

@bo_shmo I was told by the seller that the bike needed a new battery pack as the current one is only good for 5-7 miles but he also said the bike was purchased in 2019 and it would seem that the battery would work for longer than a couple of years. Faraday claims to have 85 batteries in stock on their website: https://faradaybikeparts.com/shop/spare-... but they are also asking $599 a piece for them which seems like a lot of money for a used discontinued e-bike that I picked up for a third of that price. I haven't been able to find instructions for replacing the battery cells with new ones and I did hear something about the sensors as well which is unfortunate since they don't appear to have extended the battery life in any meaningful way. So far that is the only thing I have been able to find that needs fixing on the bike...all other components are working well. Would definitely be interested in hearing more of your advice about caring for the Faraday. Thank you!

da

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Here’s a video on how to build one:

http://www.ebikeschool.com/how-to-build-...

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Look on youtube. There’s tons of videos. You buy the battery cells then spot weld them together in sequence. Then put them in some kind of waterproof case.

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bO Shmo sarà eternamente grato.
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