Bosch PowerPack Battery - Downtube Mount

[Tom Gagliardi]

Hi Mentors,

Thank you for all of the information you've shared over the years and continue to share.

I'm building my first ebike with a Bosch motor and Bosch PowerPack 500 battery. I'm working on how I'm going to attach/mount the battery to the downtube. Any input from past builds would be greatly appreciated.

Tom

[Jamie Medeiros]

It is pretty easy, Bosch should supply you with a drawing for the distance between 2 water bottle bosses near the bottom and a weird rectangular "u" shaped braze on at the top. This is the last one we built here at Firefly.
https://www.flickr.com/photos/firefl...h/50223371337/

The one awkward thing is I found it necessary to cut and splice some of the wire harness so I wouldn't have to put massive holes in the frame.

This is my personal commuter, I put over 4000 miles on it last year:
https://www.flickr.com/photos/firefl...57710872945513

[Tom Gagliardi]

Thank you. I was that you'd built a few of these and was hoping you'd chime in. I don't have the parts in hand yet.

Is the "u" shape bracket something you made or do they sell that part? I'm a steel guy.

I've been trying to figure out how I'm going to work with the jig. I'm using the motor cabinet that FBS sell. Is that a dummy motor you built to fit it in the jig?

[Jamie Medeiros]

Bosch has a steel laser cut kit you can weld to a steel bottom bracket to mimic the motor placement. Link is to a photo of ours but covered with a gas shield for welding. https://photos.app.goo.gl/UTMsEJG9czf3hxE57