(Advanced) Complete Wiring Guide For E-Bike Lights w/ 3D Printed Enclosure

Описание: Yo. This video is quite lengthy but I am giving plenty of practical electronics knowledge. If you are into that you may find this video quite valuable. Let me know if you have any trouble following or any recommendations for me. I will answer any and all questions!

For those worried about battery drain, the entire setup with all the lights on and fast charging a phone uses 52 watts.

I don't want to share the 3d print file as there are still some finer details that need to be ironed out. I can share the fusion file for you to work with: https://a360.co/4c1vJdK

The main issues that still persist:
modules are too close together
box needs to be slightly longer and wider
dc converter needs to be moved up
panel should be thicker to prevent flexing when screwed down
slots for nuts for mounting to tube should be narrower

I will get around to fixing these but for now my 3d printer is occupied with other projects!

Affiliate links:

Electrical Modules (required):
15-90V to 12V 10A DC Converter: https://s.click.aliexpress.com/e/_omE...
6 Way Fuse Box: https://s.click.aliexpress.com/e/_oET...
4 Channel 12V Relay Module: https://s.click.aliexpress.com/e/_oCj...
Panel Mount Waterproof Electrical Connectors: https://s.click.aliexpress.com/e/_okB...
4-in-1 switch: https://s.click.aliexpress.com/e/_opS...
Motorcycle fog light: https://s.click.aliexpress.com/e/_oBj...
LED Tail light: https://www.aliexpress.us/item/325680...
Phone Holder/Charger: https://s.click.aliexpress.com/e/_oDk...

Various Materials (you may have some on hand):
Screw kit: https://s.click.aliexpress.com/e/_oDJ...
Rubber strip: https://amzn.to/3FF8Q3P
Brass insert kit: https://s.click.aliexpress.com/e/_oCb...
Nuts & bolts: https://s.click.aliexpress.com/e/_oC7...
Gasket String (2.5mm): https://s.click.aliexpress.com/e/_okd...
4:1 Heat Shrink: https://amzn.to/4hzo73v
Wire Harness Tape: https://www.aliexpress.us/item/325680...
Waterproof Connectors: https://s.click.aliexpress.com/e/_oBR...
Rosin Flux Can: https://s.click.aliexpress.com/e/_oBR...
22 AWG Wire 10 Colors: https://amzn.to/4iWww20
Non Insulated Terminals: https://s.click.aliexpress.com/e/_oES...
Wire Ferrule Kit: https://amzn.to/41TzXQa
Automotive Blade Fuse Kit: https://amzn.to/4kSi1ht

Tools:
Variable DC Power Supply: https://amzn.to/4iU9OHQ
Soldering Station: https://s.click.aliexpress.com/e/_om3...
Hot air gun: https://s.click.aliexpress.com/e/_okO...
Self Adjusting 12-22 AWG Wire Stripper: https://amzn.to/4j9uWdl
Engineer PA-07 Precision Wire Strippers: https://amzn.to/3XTet4s

0:00 Brief demonstration
0:54 Choosing parts
2:36 Designing & printing the panel
2:54 Installing the brass inserts and mounting the modules
4:49 Connecting the DC module 12v to the fuse box
7:47 Getting power from the battery to the DC module
15:37 Powering the module using a bench power supply
17:15 Verifying we get 12v dc
18:48 Alternatively, you can use cable glands
19:10 The plan to connect the switches to the relay module
20:20 Powering the relay module
25:30 How to control each relay
26:08 I thought my relay module was broken... it was not
27:20 Connecting the switches to the relay module inputs
29:24 Connecting the LED tail light module
36:50 Testing out the tail light module
37:07 Connecting the fog lights
38:40 Wiring almost done. Testing everything so far.
39:10 Adding the wireless phone charger
41:56 Testing the phone charger
42:48 Connecting it all to my e-bike 72v battery
43:01 3D printed lid design considerations
44:28 Lid has been printed, revised, and reprinted
46:55 Putting everything in the box
50:29 Cutting the gasket to size
51:23 Closing up the box
53:49 Mounting the enclosure to the bike
55:05 Connecting all the accessories
56:40 Powering everything on the bike
57:33 How you would wire a brake switch to the brake light
58:00 Would you buy this?
58:50 Admiring my bike
59:50 Thanks for watching
1:01:58 Speed controller on top of box?
1:02:27 Did anyone make it this far?