Using drill batteries on electric bikes and erides is not anything new. The main advantage of using drill batteries is that you convert from an internal battery to 2 swappable drill batteries - which means that as long as you have more drill batteries to swap and rotate, you can ride for as long and as far as you want. Direct replacement batteries for these e-bikes are often more than $140, and if you already have drill batteries, well - it kind of feels like it's a free battery replacement. It might also give you an excuse to buy a few more batteries.

I have been modifying Jetson Bolt Pros with drill batteries and often get asked about how to do it and parts links, so here are the instructions below. If you are handy and have the tools, it's not an overly complicated build. 

WIRING ADAPTERS IN SERIES

Wiring two drill battery adapters together is a pretty easy, if you have the tools and parts to do so. You will need to use two drill batteries because the stock Jetson Bolt Pro systems runs off of 36 volts. When you wire two 18V batteries together in SERIES you combine the voltage and it becomes 36 volts. Wiring in series means you connect the positive wire from one battery to the negative wire from another battery. Then the two remaining wires from each battery then connect to the controller to power your ebike.

These adapters usually come with a 30a fuse, so since they are being wired together, you will only need one fuse. I cut off the fuse from the positive that connects to the negative and keep the fuse on the positive that will connect to the controller. Here's a list of adapters I have used that have mounting holes.  

MAKING THE BATTERY MOUNT

Mounting the Battery Pack to the Frame

After some research and experimenting, I found that a water bottle bracket works great with some minor modifications to the hardware. Instead of mounting a water bottle holder to the frame, you will be mounting the drill battery adapter pack instead. The bracket kit comes with two plastic inserts for the frame tube, use the thinner one to mount it to the Jetson Bolt Pro frame. 

You will need to completely remove one long screw from the frame mount. The other long screw you can back it out as much as you can but keep it attached. This will let you rotate half of the ring, and slide it in the groove of the battery cover and slide it into position. Place the frame mount about 1 inch from where the wires goes into the frame. I have found this to be the perfect location for the battery pack as it still gives you the clearance to pedal, use your carrying handle and fold down the handlebar. Tighten a little bit on each side, until the frame mount is secured to the frame and won't move. Be careful with using electric tools or over tightening the screws to avoid stripping out the threads.   

Next, you will need to rotate the water bottle bracket so it is parallel with the bike tube. Then, using the bracket as a template, drill two matching holes between the battery adapters so you can screw the battery plate to bracket. You will need to get longer screws as the ones provided are too short. You will need M5-0.8 x 16mm Button Head Socket Cap Screws, M5 Stainless Flat Washers, and M5 Split Lock Washer. Between using the longer screws, washers and lock washers, the battery pack will attach securely to the frame and won't budge. 

The final step is drilling a pass through hole in the battery cover so the XT60 connector can connect to the controller. I have found using a 1/4-20 drill bit works well as a pilot hole, then I cut out the rest of the plastic with cutting pliers. Plug it in, make sure the fuse is properly seated and test everything works before putting the battery cover back on. 

Your total cost in parts for this build will be from $50 to $70. Fifty dollars if you purchase these items from the hardware store and get just what you need, or $70 if you have to buy some of these items in bulk from Amazon. Here is the full list of parts you may need for this build. https://amzn.to/44n70i6

Our plug and play kits are sold for $65 for M18 and Dewalt set-ups and $75 for Ryobi batteries. They include all the hardware, come pre-wired and all you will have to do is mount it to the frame and drill a hole in the battery cover for the battery wires to pass through. They are made to fit on the Jetson Bolt Pro, but can easily be used on any 36V ebike. You may need an XT60 extension in some cases if the controller is further away from the mounting location.