Electric mountain bike conversion
A personal conversion project, from battery sizing and assembly to electrical integration on a working bicycle.
Building and integrating a battery pack
At a glance
- Personal electric mountain bike conversion, still operational.
- 13s4p, 19.6 Ah battery: sizing, spot welding and BMS wiring.
- Mechanical and electrical integration of a purchased motor and controller.
Read the technical details
Objective
Convert a conventional mountain bike into an electric bicycle by selecting and integrating the battery, motor, controller and associated components.
My role
I sized and fully assembled a 13s4p, 19.6 Ah lithium-ion battery, spot-welded the 0.15 mm nickel interconnections and wired the Daly BMS.
Method & key decisions
I adapted a commercially available battery enclosure and integrated a purchased hub motor supplied already laced into its wheel, along with the controller and electrical accessories. This required linking electrical sizing, component compatibility and practical mechanical installation.
Outcome & lessons
The bicycle is still operational and reaches around 40 km/h in personal use. This project gave me practical experience in building a battery and integrating the mechanical and electrical components required for the conversion.