DIY Ebike S01E05: Home made power tool silicone mold for Kobalt 24V electric bike battery

DIY Ebike S01E05: Home made power tool silicone mold for Kobalt 24V electric bike battery

Fifth video in this Ebike series. This time I will be making a silicone-corn starch mold (mold for Americans, mould for the rest of the world!) to form the base of the power tool so I can insert my batteries in. Of all of the ebike projects, this is the project that consumes the most of my time! (Partly because I failed so many times!) So seat back, relax, and enjoy!

Readers Comments (50)

  1. On the two batteries you made, How long does your bike run on them? And are they still working?

  2. Thanks for awesome video. I’m a lazy guy and would not do this myself but i can appreciate all the hard work that went into making this battery and e-bike

  3. very clever

  4. A hack I’ve been waiting for! Thanks my man! …Love your channel, btw!

  5. GeamanU EntertainmenT April 12, 2021 @ 11:51 pm

    on you bike connected with 2 battery , have more volt or amp?

  6. I love it! Thank you for this hack. Hope you are well thru this virus thing!!

  7. im a big fan, great job mate, keep up the good work !!!

  8. hello, I would like to let you know that you have very good videos. ready enjoy what you do.

  9. whether I do it or not exactly like you, I’m not sure, but I admire you creativity, and am sure that when you are finished with the series, you videos will definitely be my guideline for making electric bikes for my grandchildren. Then for me.

    I’m a big guy 250#, so maybe at some point, when the time comes you could advise me on a frame that won’t break when I’m going 30 mph so I don’t die. 馃槏

    Also, kits for small bikes for small children?

  10. Very clever and creative. Thumbs up.

  11. This . . .. . seems so much easier and funner than what I’ve been doing for a few months. 馃樁
    I’ve been making battery adapters out of plywood that I chisel to shape

  12. Power Battery Channel April 12, 2021 @ 11:55 pm

    Great! Thanks!

  13. minivan traveling April 12, 2021 @ 11:58 pm

    Wear a vent mask, then you no get headache.

  14. thanks for the vidoe, excatly what i was looking for.

  15. I just stick two pennies into the connectors and let the current weld them on LOL

  16. Benja's Uber 1337 Hobby April 13, 2021 @ 12:01 am

    New sub I LIked your video 馃檪 I have been enjoying your bike build 馃檪 Thanks for sharing 馃檪

  17. Nice inventiveness, now take a look at this company that uses modern 3D printing tech to create these a whole lot easier: www.

  18. 菨蕦菨蕠s u蕧op 菨p谋sdn April 13, 2021 @ 12:01 am

    Thanks for the video. Love your accent. I am trying to make an adapter for my craftsman cordless power tools so I can use lithium batteries instead of the old NiCd batteries. Thanks for sharing. I might can figure out how to make an adapter to use Porter cable lithium batteries with my old craftsman cordless power tools hopefully. Or I might try to use cheaper lithium batteries with my craftsman cordless power tools. Thanks again

  19. Well done, creative

  20. Excellent idea , good stuff man . Thanks for sharing

  21. amazing…

  22. Excellent. It does seem like something I could screw up though.

    2 questions:

    For a less screwupable alternative, you could embed the aluminum clips in a block of wood and strap them down, couldn’t you?


    The middle metal clip you don’t need to put in….it’s only purpose is for charging, and the piece is on me for discharge….Am I correct?

  23. My Budgie Journey April 13, 2021 @ 12:06 am

    nice work, I’m impressed:-)

  24. Great job.

  25. IF you have access to a 3D Printer, you can check Thingiverse for a 3D printed version (template) which accomplishes the same thing and is much cleaner. You do need to add the metal contacts (as you did with your mold. I made 6 of them and were surprised at how nice the fit is! I went from a maker space (costing about $5 each) to purchasing my own 3D printer, just because of this experience, PS…I GREATLY enjoy your videos and find them EXTREMELY informative.

  26. You can get battery mounts on amazon to fit these

  27. Well done!! Watched til the iPhone battery died… lol

  28. Michael Thibault April 13, 2021 @ 12:12 am

    This is an interesting and useful video as it illustrates, very well, how to create molds to exactly replicate a part in-hand. I can see how it might be used to create a top-and-bottom pair of objects to mate two physically dissimilar but electrically compatible battery systems (e.g. Brand A batteries for use will Brand B cordless appliances).

    However, this project is really about cabling i.e. creating a means to reliably and securely ‘tap’ a particular battery’s terminals and carry power to some device not equipped with the necessary physical interface. As such, the goal might well have been accomplished more simply.

  29. This was fantastic and I was able to make an adapter for some old Skil 18v tools that still work great.

    I make a couple of changes to the process. One is for the non-stick part and instead of vegetable oil I used vegetable spry (PAM). That got into all of the hard to reach places. The other was to use a plastic food bag and cut the tip and piped it into the tool get 100 percent coverage in the hard to reach places.

    This works great if you don’t have access to a 3D printer.

  30. Amazing
    Thanks for the video
    OH YEAH!

  31. Eric Schleicher April 13, 2021 @ 12:16 am

    This is great… but you need a 3d printer. If you have access to one, I can send you a 3d-model for a generic adapter for the Kobalt battery.

  32. awesome job bud

  33. You are one of the best explainers on Youtube. You say the minimum number of words but you get the point across very clearly!

  34. Fun in the woods hairy dude April 13, 2021 @ 12:23 am

    Hook up those little 5 volt friction generators…… ebike with an alternator lol.

  35. Brilliant ! Keep doing similar diy projects 馃檪

  36. Chef Kendra Nguyen April 13, 2021 @ 12:25 am

    You’re just practical. I appreciate that. You come up with solutions for stuff without over engineering everything. Quick question, can you buy all this stuff in this project from Home Depot or Lowes?

  37. 24:18 charging tool battery packs

  38. Polyester resin with hardner. Any auto parts store. U can use cotton flox too./cheap. Aircraftspruce. In corona.

  39. I love watching your videos, a combination of great creativity with bits of humour.

    I鈥檓 with you when it comes to keeping the 18650 cells in the power tool battery packs. Instead of going to the effort you have made to make your own terminals I simply purchased a bunch of Makita spare part terminals for my Makita batteries. They are relatively cheap and fit perfect as you would expect.

  40. Assassin Mongoose April 13, 2021 @ 12:27 am

    I think you needed to use a release agent 7:30 so that your silicone mold will separate properly from the drill.. I give ya 5 stars for effort, thanks for putting on youtube. Oh and should cover your tools 5:20 with Glade Cling-wrap or some kind of Cellophane Wrapper. Good Job

  41. VINTAGE CAMERAS April 13, 2021 @ 12:27 am


  42. Michael Thibault April 13, 2021 @ 12:30 am

    Once you’ve selected a mass-manufactured plastic box (5 sides) that snugly fits around, and just contains, the part you’ll be using for reference (e.g. the base of your power tool), does it not make sense to: pour a silicone negative of the interior of the box; pour a silicone negative of that (to re-create the molding box in an easily-removed flexible rubber form); make your first negative of your object, in silicone, within the silicone molding box; and _then_ make the negative of the negative of the object of interest? This way, there’s the opportunity to practice with the mix before it’s ‘complicated’ by complex shapes, but also you get the benefit of a long-lived, flexible box that you can re-use.

    One question I have concerns the apparent shrinkage of the fiberglass resin: does the shrinkage depend on the amount of hardener added? IOW, can less hardener + longer cure times result in less shrinkage with the same net hardness?

  43. What about the harbor freight drill, lot cheaper.

  44. Christopher Last Name April 13, 2021 @ 12:34 am

    I used play doe to make a molded !

  45. man, your dedication to DIY is awe-inspiring!

  46. Hey my Freand can I use 2 of the same battery for a 36v pack on a scooter schwinn 350 watts ??

  47. Ok thank u my freand love u videos keep up the good work u diy r the dest 馃槈馃槉

  48. Just found this. Very good. I did the same thing with DeWalt 36 volt batteries for my 72 volt ebike back in 2006. Apparently great minds think alike. Oh yeah. It still works.

  49. Kenneth C. Adams April 13, 2021 @ 12:38 am

    You should mention that using the corn starch helps the silicone set up and dry properly . I tried pure silicone and could not get it to dry where the silicone was very thick . Days later it was still liquid inside . Corn starch seems to cure this problem [pun intended] . Also measuring 30% corn starch to silicone ratio is not easy . how do you measure it ? Eyeball ?

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