LiPo Armor How To

LiPo Armor How To
Tony Arnold - StampedeProject.com

Sooner or later your car will take a big hit and in the process damage to your un-protected LiPo pack(s) is possible and then... of course we know bad things can happen.

To make LiPos safer and less prone to damage, more manufacturers are now offering packs pre-armored and encased in plastic shells such as Enerland Racing's new Hard Case Car Packs. Packs with higher 3S+ and larger MH ratings though are too big and varying in size and left unprotected with only a few layers of shrink wrap for protection. The result is that we need to take a few minutes to fabricate armor for odd sized or larger packs to prevent damage.

I know, I know, I am using the "F" word again - Fabrication, but believe me, it's as easy as wrapping a present. In this example I will be using a scrape Lexan body piece, however 1/32" polycarbonate plastic from your local hardware store, or even plastic from an empty milk jug will work. Permanent bends in polycarbonate, AKA Lexan, can be easily made as with most flexible/bendable non-shattering plastics.
WARNING - Do not use Acrylic or Plexiglas as it will shatter dangerously like glass.

1. Assure you have enough plastic to encase the pack.
2. Use a fine-tipped Sharpie to trace around the pack on the plastic.

   

3. Cut the corners to form foldable flaps.
4. Use a ruler and firmly fold each flap.
   

   
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5. Place the pack in the plastic & use a fine-tipped Sharpie to mark the height on flaps.
   
6. Use a ruler and firmly fold each flap to form the final seams and trim excess.
7. Slip in a logo or image for a custom pack (optional).
8. Use heavy packaging tape or electrical tape to secure the armor.
   
9. Enjoy a more safe and durable LiPo pack.

[CAPTION - For the ultra-lazy MaxAmps has pre-cut Lexan covers for their standard sized cells. ]

Once you have pack armoring down, you may want to try using different materials and getting creative. I have even added 1/8" aluminum extra armor to packs if they are directly exposed to potential damage.

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SOURCES: MaxAmps - www.MaxAmps.com, Enerland Racing/PolyQuest - www.Enerland.com, StampedeProject.com