First build using Flipsky 6384 140kv waterproof motor, Flipsky ESC 75200 200A, Flipsky VX3 PRO wireless remote. After reading posts on this site for endless hours I finally decided to throw my hat in the ring and give it a crack. I will eventually provide a full component list coupled with pictures and details of the build to give back to the community.
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I sourced most the components via AliExpress, except the bus bars that I had made custom from WELLGO through Alibaba, and the prop through Foil Drive.
Component list:(all cost is AUD)
Main components:
Flipsky 6384 140kv waterproof motor $224.99
Flipsky ESC 75200 200A $239.99
Flipsky VX3 PRO wireless remote $181.99
IP67 Waterproof grey 260 x 160 x 100 $47.99
Foil Drive Three Blade Propeller Hub Set $440
3 Core x 4mm Power Flex RVK cable 3M $19.62
TJA1050 Can controller interface $4.72
Micro SD Mini TF card reader module SPI $3.96
Alluminium Heat sink 60 x 150 x 25 $30
SD card 1TB $8.88
ESP32-C3 OLED development board $6.89
Total: $2009.03
Battery:
Fly paper (roll) $5.93
40 x Molicel 21700 P45B $436.82
XT90s $16.39
2 x Silicone wire 22AWG (grey, red) 2m $4.80
Fiberglass Tape (25m roll) $18.16
10k NTC Thermistor $2.89
2 x Silicone wire 8AWG (black, red) 2m $30
XH2.54 13Pin connector (male, female) $1.40
WELLGO Power Battery Pack Busbar $47.40
PVC Battery Heat Shrink tube 350mm x 1m $5.52
PVC Battery Heat Shrink tube 180mm x 1m $2.50
Exotronic Inline Single Midi Fuse holder $6.90
Midi 58V 100A fuse (x5) $5.39
70mm x 33m High Temperature Polyimide Tape (roll) $48.00
Total: $633.10
Other materials:
3D filament used was ABS, ABS -CF and PLA.
Tooling considerations:
3d printer (Bambu X1c)
801H Spot Welding Machine $328.69
Battery Charger
Icharger x12 $319.69
HPE HSTNS-PD19 1200W DPS-1200FB-1 A $39.00
Skyrc Temperature Sensor $6.24
Total: $364.93
Project total: $2535.81
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test flight video ← Video of function test
Being a large bloke (120kg) I wanted to build a simple system that would have enough grunt to get me up on the foil and that I could transition from a foil assist position for winging and SUP to a lower Efoil position for when there was no wind of surf. I also wanted to make sure I had logging so that I could obtain some usable data to further refine and gather information, if I decide to take on a full dedicated efoil project in the future.
As I am already having a crack at wing foiling I already had a 170L learner board which has lots of space so used it for the test vehicle paired with an axis 19mm mast Axis BSC 1120 front wing and 500 rear stabilizer. I was pretty confident that I would be able to get up on foil but was still unsure of the Max current needed to get me there and wanted to allow enough headroom for when I do eventually drop the board and foil sizes. This led me to the 12s3p battery design with a comfortable 100A max as a starting point. More information when I get a chance.
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For those looking to get started the whole site is a treasure chest of information. Hangloose deserves a lot of credit with his sharing of 3D files which made my life a lot easier I highly recommend reading Hangloose build. I modified his motor mount and then did a scan of my Axis mast and created a fairing to hide the motor cable as I felt it was causing quite a bit of drag which I confirmed with some Computational Fluid Dynamics analysis. I will look to upload them if anyone shows any interest in trying them.
First cross section is of the of the original cable mount. You can see the dark blue drag turbulence it causes. While running wires inside the mast is the best solution I did not want to drill may mast as I am yet certain on what postions I wish to use it. so I created a fairing that slides over the mast and has a channel to run the cable.
Which resulted in the following CFD results. You can see that the drag is reduced significantly and I do notice a difference.
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Welcome
Congrats on successful build and flight. 
The VESC tools logging function will provide lots of data
Nicely documented build topic as well!
I did about 6 months of research before building the battery and a lot of calculations and changes in my design for about another 6 months after. The first question I had to answer was what configuration was I going to use which was answered through the desire to make sure I had enough power to get up on the foil and as I was not sure how much I was going to need I opted for a 12 cell in series for a total of 43.2V as that was the largest hobby battery balance charger I could find and figured that it would then allow me to try with smaller batteries later on. As I had the balance charger and the Flipsky 75200 has VESC I saw no need for a BMS, as most BMS units that allow large output currents are quite chunky and figured the VESC can handle the current and voltage management.
I choose the Molicel p45B cells as I opted for a 3 parallel configuration giving a total of 13.5Ah and the ability to run 135A constant with temp monitoring if required. As the 6384 specs state 4400W max I did not plan to exceed 100A but wanted the head room as I may use the battery for other projects. Turns out with my current board configuration I was flat out getting to 70A from the battery with the ESC maxing out at 130A so it has been a good fit.
Originally, I planned to just use nickel strip with a cheaper spot welder but it came apparent that to support the potential higher current that copper would be the best way forward. This lead me to trying to achieve the Nickle Copper sandwich technique which is quite popular for higher amperage pack building. However, the AliExpress supply of copper large enough to laser cut out my busbars was not available and I saw the WELLGO busbars on AliExpress so I reached out to get a quote for my custom designed bus bar which was relatively cheap, with the only draw back being that I had to order a minimum number of 5 sets. I thought that this would be good anyway as I would most likely stuff one set getting the spot welder setup. Turns out they gave me some scrap pieces to practice on so I have 4 sets left to build more latter or maybe sell them if there is any interest.
I took a great amount of time designing the battery cable routes to make sure all wires never crossed over. I definitely spent to much time creating the end piece with the 13 pin connector so that the wires would not rub. As part of the battery monitoring I used a 10k NTC thermistor mounted in the middle of the pack that runs to a connect for the 75200 ESC which is usually used for a motor temp sensor so that my logging can show how the battery deals with the heat. I also added an inline fuse of 100A just as a safety factor incase things go horribly wrong.