E-Bike 120VAC Charger Installation

MuttonChops

Recently added an E-Bike to my toys list. While other electricity powered toys have built in battery charger, e-bike has a stand-alone {monster 7x3.5x2 inch} brick charger that runs real hot when in use. Another thing to loose track of, trip over, and to store. So decided to “build one into T@B”.

This charger also recommends plugging in the 120VAC last to charge and unplugging 120VAC first to stop charging.

Installation goals were; easy operation, no 120V Plug-in/out task, location in more or less wasted space.

Current solution was to add a Switched 120VAC source with 'on' indicator light and locate the hot brick in the driver side wheel well.

Will see how this works out. Concerns are 48VDC Plug getting in way when not in use. Not being able to see charger Red/Green light without lifting wheel well bench seat.

Homebodyatheart

@MuttonChops I’m following this as I’ve got the same new toy. Congrats and keep us posted!

MuttonChops

UPDATE - - - Moved Charge Status Indicator LED - - -

MuttonChops said:

. . . Concerns . . . Not being able to see charger Red/Green light without lifting wheel well bench seat.

The more I thought about not being able to quickly see the Charger Status LED the less ideal my initial installation seemed.  So today Moved the LED so it is visible without lifting the Wheel Well Bench Seat.

Change Process {Skill level 2+}
- A - desoldered indicator LED from charger PCB
- B - added ~10-12 inches of wire to LED, confirmed Charger Operation
- C - popped (plastic) Light Pipe out of charger housing
- D - drilled hole for Light Pipe in T@B; square peg, round hole. Sized drill bit for tight fit.
- E -  mounted LED next to Light Pipe, confirmed operation, then glue gunned wires in place
- F -  used plastic lid of small jar to cover LED - - - just so it is not bumped

Then Used E-Bike Battery to TEST Installation.  Work Great!

Bayliss

Pretty slick, @MuttonChops.............thinking outside the box.........literally!  

Homebodyatheart

@MuttonChops you do great work and I’m impressed with your mod! When you start using terms like “unsoldered” I’m certain this is way out of my league.  Thanks for sharing!