DIY 48V E-Bike Battery Upgrade Guide

If you're interested in DIY electric bike batteries, this article is definitely worth a read.

If your e-bike battery is failing, you can consider upgrading or modifying it. For example, if you have a 48V 12Ah battery, you can measure the casing dimensions and try assembling a new pack using 18650 cells to create a 48V 20.8Ah battery pack.

In this project, the 18650 cells used are from BAK Battery (Bick Battery). The original battery pack is 48V 26Ah. If the dimensions don't match, you'll need to disassemble it completely and reassemble it from scratch.

Next, you can open the battery casing and remove the battery pack.

Then, you'll need to disassemble the battery pack further and remove the protection board.

This particular battery is from Phylion, 12Ah.

As shown in the image above, disassemble the BAK 18650 cells carefully.

Next, you can start assembling the pack using a T12 hot glue gun.

Then, you'll need to create isolation using an epoxy resin board.

After soldering is complete, you can test the battery for charge/discharge functionality and short-circuit protection.

For this DIY project, a total of 104 BAK 18650 cells are required.

The end.