NexGen3D: Dewalt eBike BoostPack - 18/36/72v

I wanted an easy way to extend the range of my bike, and to leverage the batteries I already own, so I created the BoostPack.

Features:

• Can use the following Dewalt batteries:
  • 5ah 18v Standard
  • 5ah  18v PowerStack
  • 8ah 18v Standard
  • 8ah 18v PowerPack with Tabless Cells
• Uses an XT90 connector
• Has secure tie points if required
• Can be configured to the following voltages (Using 5ah as example)
  • 18v 20ah
  • 36v 10ah
  • 72v 5ah

I'm unsure if the 54v Dewalt batteries will fit properly as I don't have any to test on it, but there is a good chance they will.

You can charge this pack like you would your eBike battery, or you can pull them off and charge in any Dewalt charger, you can also carry spares and swap them as they go flat.

To make this you will need the following:

• 4 x Dewalt battery mounts → Aliexpress link
• 16 x M3x16mm SHS/BHS
• 16 x M3 threaded inserts
• 1 x XT90E Panel Mount → Aliexpress link
• 1 x Good Backpack, this is the one I use → 511 Tactical link

I printed the lid and casing from PETG-CF and the cushion part from soft TPU.

Just in case someone would like to know, the standard 8ah Dewalt packs use Samsung 21700 40T cells in a 5S2P configuration, giving these packs a sustained output of 70a, this is more than enough to boost your bike and eliminate voltage drop on hard acceleration.