Battery building

Packs built to order

We build packs around the board and the rider: cell choice, pack shape, BMS and fusing all decided together. Every pack is spot welded, fused per group, pressure tested for fit and logged with its own capacity test before it ships.

Build + fix

New packs, rebuilds and repairs on GT, XR and Pint

Spot welded

Nickel strip, fused per parallel group

Tested

Capacity and drain logged before shipping

3–5 wks

Typical lead time from agreed spec

Three packs on the bench

Two built to order and one brought back from a fault — each started as a conversation about how the board gets ridden.

Pint V15S1PMolicel P50S

Insane torque for such a small board

The brief. A Pint V rider wanted more push out of corners and up short climbs, without adding bulk to a board they carry every day.

What we built. A 15S1P pack on Molicel P50S cells — high-drain cells rather than high-capacity ones, so the voltage holds up when the motor asks for it. Single-parallel layout keeps the pack short and the mass over the wheel, with fused groups and a printed end cap doing the strain relief.

Result. Torque well beyond what the board came with, and no sag on the climbs that used to push it. Range stayed where the rider needed it.

Nominal

63 V

Capacity

5.0 Ah

Weight

1.7 kg

XR chassis15S3PSamsung 50S

Commuter pack rebuilt around a tired original

The brief. A five-year-old board losing range on a daily nine-mile commute. The rider wanted reliability and charge speed, not maximum range.

What we built. A 15S3P pack on 50S cells reusing the original enclosure, with a new BMS, replaced main leads and a printed PETG tray that stops the block moving in the box. Balance leads rerouted away from the rail edge where the old ones had chafed.

Result. Range past what the board did new, with a full charge inside two hours on the stock brick. Two winters in service so far.

Nominal

63 V

Capacity

15 Ah

Weight

4.2 kg

RepairChi BatteryBalance lead fault

Broken balance lead on a Chi pack

The brief. A Chi Battery pack that would not report cell voltages properly. The board was refusing to charge past a point and the rider did not want to replace a healthy pack over one wire.

What we built. Stripped the pack down far enough to get at the balance loom, traced the fault to a broken wire, resoldered the joint and resealed the pack.

Result. All groups reporting again and charging normally. The pack went back in the board rather than in the bin.

Fault

Open lead

Fix

Resolder

Cells

Untouched

How a build runs

Conversation

Board, riding, range you want and weight you will tolerate. We say what is realistic.

Spec

Cell choice, series and parallel count, BMS and fusing, plus any printed trays or caps.

Build

Cells matched and spot welded, groups fused, pack potted and fitted to the chassis.

Test and log

Capacity and drain test recorded, results handed over with the pack.