Here's some pics of my waterproofing attempts
of the BL-36 using hot glue.
I've also used shrink wrap and electrical tape on all connectors.
I used hot glue to make a gasket on the controller top,
while also hotglueing any openings.
I dont intend to ride in the rain on purpose,
but I want to be prepared for the unforseen downpour.
The first 4 pics are of the BL 36 controller,
just to show the caps and insides.
Looks like they already used some sort of glueing rubbery substance
to dampen the components.
I did hotglue the 2 big caps so they were fixed to each other and the board.
I then hotglued all the seams and openings I could find.
For the hub motor, I made sure to glue the wires going into the hub,
and form a drip loop.
I also found some plumbing waterproofing tape at a hardware store.
It is Duck brand, and very stretchy and rubbery.
I have put it on the connectors, and then covered with regular electrical tape.
Any success or failure stories with waterproofing attempts? There's a guy on Youtube that gives a video demonstration of waterproofing most components (batteries not included). I'm planning to start using the bike to go to work most days, as long as the forcast is not rain all day. The guy on Youtube uses silicon sealant instead of hot glue. I've used the silicon around the house for many things, and it will stick to anything, and keep water out. I've noticed on the tube that the silicon can be used on surfaces that get up to 400 degrees, which should easily be enough for any component. I think I might put some of that on the battery connections as well. Will post again after I make the modifications and get wet.
Gasoline? No thanks.
RL
I think silicone should be fine.
I like hot glue becoz it dries fast, and is easily removeable,
and also cheaper.
The controller on the BL36 never even get close to being hot.
Maybe with overvolting , it might get get a bit hotter,
but I hope no where close to 400 degrees.
Yes, I'd like to hear if your silicone works well.
I dont plan on testing my waterproofing on purpose.
I think I will have to get Goretex bags for the batteries,
or water proof bags, if I seriously plan to ride all year.
For now, I only plan to ride in good weather on purpose.
However, unforseedn downpours and puddles are always possible.
I had to go through another sprinkler puddle this week,
and got splashed.
Nothing got wet though, except myself.
I think you should also get fenders for your bike, ifyou plan on all year riding.
That will prevent upspray on the batts and controller.
I won't leave home unless it's dry when I leave, and no more chance of
rain than isolated showers. There are a number of days that I don't
ride because of a slight chance of rain. I have fenders on the way, and
have seen a nice Topeak bike cover on ebay that I will use at the office
on less than sunny days. Never know when I might have to go home in the
rain, but I'm not planning to get wet just for the fun of it. My kit is
a BD36, but the principles should be the same.
Gasoline? No thanks.
RL
I rode my mtb this morning through puddles for 15 miles with no problems. My motor has a drip loop, and I have a rear fender I made out of a piece of 1/2" closed cell foam tied to the seat post and post rack. Just a chunk about 3 or 4 inches wide and 18" wide. just in case, I tied a grocery bag around the controller mounted on the back of the seatpost. The bag never got wet, and splashing through puddles at 25mph is no problem since the water slings off and never gets near the hub. I carry a couple big trash bags in my messenger bag in case of getting caught, but if I have to ride to shelter, I'll bag the battery and controller, and peadle it with the battery unplugged.
Be the pack leader.
36 volt sla schwinn beach cruiser
36 volt lifepo4 mongoose mtb
24 volt sla + nicad EV Global
One big concern is the throttle. The guy on Youtube said that
if the inside of the throttle gets wet, it may stick wide open!
I think I could waterproof everything else pretty well.
Youtube video is posted as something like "weatherproofing electric
bikes."
Gasoline? No thanks.
RL
I'm going to 48v soon, so the standard battery bag won't work.
I've ordered a small Dewalt tool bag from ebay to hold the larger
battery pack. Not sure if this one is waterproof, but I know that
some are.
Gasoline? No thanks.
RL
Open up the throttle, and use some hot glue in there
near the hall effect sensor.
This should waterproof the wires and circuit.
Not too much glue, but just a bit to cover the wires and contacts.
Also the throttle has to be able to rotate , so too much glue might affect that.
As for the throttle sticking open, I think it's best to wire a kill switch into the controller.
I found this site.
http://www.thewaterproofstore.com/bags.html
Looks like all sorts of cheap waterproof bags available there.
This waterproofing coating might work on the outside of the battery bag,
though it does say Flammable, but hopefully when dried it is fine ?
http://www.rei.com/product/697792
I think the zipper, is really where it would leak though.
I am thinking of just putting some plastic sheeting ove rthe batteries,
or use a Giant Ziploc bag over all the batteries, leaving sealed holes for the connectors.
Sla's won't mind getting wet that much. It's the controller and throttle that are the fussy parts, and a drip loop should do your hub as long as you don't submerge it. But you still would rather ride unpowered in the rain, and hide till it stops if you want to save your controller. A sprinkle won't be a problem, I mean real soaker rain.
Be the pack leader.
36 volt sla schwinn beach cruiser
36 volt lifepo4 mongoose mtb
24 volt sla + nicad EV Global
Got my waterproofing done yesterday. Did pretty much what the guy on Youtube shows, but went all the way around the base of the controller. Not sure if there would be a way to waterproof the switch on there. Will post results if stuck in the rain at some point.
Gasoline? No thanks.
RL
Finished the waterproofing yesterday. Will post results if I end up in the rain. Not sure how to waterproof the switch on the controller, but otherwise did the same waterproofing as the guy on Youtube, other than sealing around the entire base of the controller.
Gasoline? No thanks.
RL
Sorry for the double posting. Seemed that the first one didn't post when I checked,
so I thought I messed something up.
Gasoline? No thanks.
RL
For the switch on the controller,
just open the top, glue or silicone the inside where the switch meets the cutout hole,
and you can also add some glue/silicone on the outside.
This should provide enough sealing.
Something about silicone..
Here's a tip a friend of mine gave me. Take the black silicone sealer (it's seems to be the stickiest) and dilute it with white gas. You gotta stir real hard but you can get it as thin as you want. Then you can brush it on and when it dries it's very tough and still flexible. Works great on fabric. Takes about a day to dry.
Never done this, but think it would make a great conformal coat for circuit boards. Take care though on the power components (the parts that get hot) as it is a good thermal insulator.
Stock BL36 on a 10yo Schwinn Searcher
She got wheels in her smiles, she can coast along for miles...
The controller is mounted mostly under the seat, and other than a slight amount of silicone at the edges of the switch cutout, the contoller is sealed. The DeWalt tool bag may not be waterproof on the outside, but the liner seems to be. The thing I like about the tool bag is that it is very sturdy.
Gasoline? No thanks.
RL
Haven't ridden in the rain yet, but wanted to update re: throttle
waterproofing. The guy on Youtube suggested a thin film of silicone
around the seams of the throttle, which is what I did. The thin film
that I put on there is starting to come off. I've never seen silicone
do that before. Throttle must be a bit too slick. May try a little
thicker coat.
Gasoline? No thanks.
RL
I bought a Kayaking waterproof bag from REI.
I intend to put the controller in it.
I would stil have to cut some holes for the wires though,
and try and seal these with hot glue.