These are the full assembly instructions for the Helium Enclosure, the battery case for Fliteboard Series 2 and newer.
What’s in the box
Every Helium Enclosure ships with five parts. Check them all before you start.
| Part | What it does |
|---|---|
| Lower frame (main enclosure) | Holds the battery pack. Glass fiber reinforced ABS. |
| Lid | Closes the top. Glass fiber reinforced ABS. |
| Gasket | Seals the lid to the frame. |
| Binding barrels | Bolt the lid to the frame. 20 included. |
| Threaded inserts | Hold the Amphenol SurLok Plus connectors in place. Already installed. |
Inside space: 266 mm side to side (10.47 in), 248 mm front to back (9.76 in), 73 mm high (2.87 in).
What you supply
The enclosure is the case only. You bring the battery and the parts that go through the case. Cells and BMS must handle at least 120 amps, the most the Flitebox pulls before it cuts out.
| Part | Notes |
|---|---|
| Battery | 21700 cells recommended. Tenpower 60XG is our first choice. Great Power 60Q or Reliance RS60 are also good, and the Reliance RS50 for cold climates. If cost is no consideration, the Linkdata 70P is also an option, though its cycle life is not as good. Avoid the EVE 50PL. |
| BMS | Daly Active 150A recommended, from the DALYBMS Official Store (opens in a new tab) (choose the 150A, 7S-17S option; the page may open on a different option, so select it first). Uses its key function for the on and off switch. |
| Wiring and bus bars | Rated for at least 120 amps. |
| Switch | Latching push button or toggle switch (not momentary) that fits a 12 mm hole. A momentary button will not work with the Daly BMS. We recommend this waterproof metal push button switch (opens in a new tab): choose NO LED, Self-locking (1NO) and 12mm (1NO), not Self-reset. Or this 12mm mini push button switch (PBS-33B) (opens in a new tab): choose a color marked Self Locking, such as Black Locking. |
| Pressure relief valve | Fits a 12 mm hole. We recommend this metal waterproof vent plug (opens in a new tab): choose M12x1.5, with nut. Or this plastic waterproof breather valve (opens in a new tab) (pack of 10): choose Black, M12x1.5-10. |
| Amphenol SurLok Plus connectors | Orange SLPRATPSO (opens in a new tab) and black SLPRATPSB (opens in a new tab), one of each, from Digi-Key. Terminals take M6 nuts (copper recommended). We recommend these copper M6 flange nuts (opens in a new tab): choose M6-2pcs. |
| M4 screws | M4 x 8 mm, to attach the connectors to the threaded inserts. |
We don’t sell third-party parts and can’t guarantee them. Check that every part suits your build.
Want a rough total for the whole build? See How much will a complete battery cost? in our FAQ.
Before you start
Only build this if you are confident working with lithium-ion batteries, or have a qualified technician do it. A mistake can damage equipment, start a fire or cause injury.
- Work on a clear, non-flammable surface with nothing metal loose nearby.
- Keep the pack at storage charge (40 to 60 percent) while you work.
- Cover exposed terminals and use insulated tools.
- Read our Battery Safety page first.
- The enclosure is water resistant, not waterproof. A good seal depends on careful assembly.
Assembly
Step 1: Connectors
The threaded inserts come already installed. Put dielectric grease on both sides of the orange SLPRATPSO and black SLPRATPSB SurLok Plus connectors to help with waterproofing, then mount them to the inserts with M4 x 8 mm screws.
The connector terminals take M6 nuts; copper nuts are recommended. Tighten the M6 terminal nuts to 3 N·m (about 27 in-lb).
Optional: add a bead of silicone around each connector inside the enclosure for extra protection.
Step 2: Switch and valve
Fit the switch in one 12 mm hole and the pressure relief valve in the other. Either part can go in either hole.
Optional: add a bead of silicone around each one inside the enclosure for extra protection.
Step 3: Pack and BMS
Build the pack in a frame that fits tight against the edges of the case, so it cannot move around inside. Leave enough room near the front of the enclosure for the switch and vent, since they stick out a little into the inside of the case. Place it in the lower enclosure, connect the BMS, and wire the main leads to the connectors. Wire the Daly key function to the switch.
Step 4: Gasket
Coat the gasket generously with dielectric grease on all sides, then seat it on the lower enclosure.
Optional: add a bead of silicone to the innermost ring on the lower enclosure before placing the lid on top.
Step 5: Lid
Set the lid on and fasten it with the 20 included binding barrels. Tighten them in a criss-cross pattern, like the lug nuts on a car wheel, so the lid pulls down evenly. Tighten them snug, not super tight.
Final checks
Check these before the battery goes in the board.
- The gasket sits evenly all the way around, with no pinches or gaps.
- All binding barrels are snug.
- The switch turns the battery on and off through the BMS.
- Pack voltage at the connectors matches the BMS reading.
Torque source: Amphenol SurLok Plus Series catalog (PDF) (opens in a new tab), page 11 (5.7 mm size, M6 nut, 3 ± 0.1 N·m).
Posterduck Customs LLC is not affiliated with or endorsed by Fliteboard. Fliteboard, Flitecell and Flitebox are trademarks of their owner and are used here only to describe compatibility.