On board battery charging system

Discussion in 'Electrical' started by UP Rider, Jun 29, 2014.

  1. UP Rider

    UP Rider New Member

    Getting tired of pulling cells out for charging and the case cracking on the elcheapo wall charger. The wife said to me that it would be kinda nice to just " plug in the bike at night. Que the light bulb over head. Why not ?

    parts list

    one- busted and disassembled 18650 wall wart Output 4.2 V 600Mah
    similar to this http://www.ebay.com/itm/291127724724?

    up to ( haven't decided yet ) 5 2X battery holders 3.7 V 18650 http://www.ebay.com/itm/251548956095?

    to be determined H X L X W project box

    2X Cree U2 LED headlightshttp://www.ebay.com/itm/141130730133?

    up to 10 of 18650 3.7 V batteries http://www.ebay.com/itm/190911430355?

    control switches mounted on center control station. Another project box ? Off the shelf ready made more than likely.

    LED tail light ( Wally World special ) 3 volt in parallel ? 1.5 volt in series ? Must investigate. Or any ideas out there to identify ?

    replacement lamp plug and cord ( local toy store aka Menards )


    mount the battery holders in project box (note here that the holders are in parallel to increase run time)

    unscrew the cheezy rubber band mount and fab up an "L" shaped mount to go on the front light bar ( six inch piece of 1 X 1 aluminum angle )

    wire from the box to handlebar mounted switch to lights front and back. Probably going to have to crack the case on one to see if I can jump the push button switch on the back of the light housing If not wire direct and remount the light bar higher up for ease of operation

    Cut off the battery terminals on the charger board and solder to a " buss bar "

    The charging board is pretty small and will fit easily inside the battery box if the box is big enough.

    Any thoughts, concerns, or comments ?

    Thank You in advance and My previous post on 18650 batteries was premature to getting this far

    UP Rider

  2. UP Rider

    UP Rider New Member

    Update #1

    I took the shrink wrap off of the battery pack that came with the headlight and found that the 4 cell pack is made up in a 2S2P configuration. A question for all that I know has probably been asked before. Anyone know of a good tutorial that explains a little more about batteries and how to configure a pack ?


    UP Rider
    Last edited: Jun 29, 2014