There were some good deals for $10 on the 1P pacs at Lowes a while back. These we can take on planes too. https://youtu.be/GXBvqV_itek
We are testing packs in serial connection that have maximum 100WH, because that is the exception to carry them by air travel. so you can carry 5 or 10 of them with most airlines if below the above size…
We use Aldi battery packs that are available in Europe Aldi stores very cheap… we put them in a donking station and it works already to fly for about 25min.
This would help to overcome the airtravel problem with efoils;-)
Our Inflatable board with motor system is carried already by air and works easy in a samsonite bag;-)
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I see that the Aldi packs use Samsung 25R cells. Pity they are only 10S packs though. The charger is pretty heavy charging the packs at almost 2C. That will reduce life cycle of the battery a bit. But as you say, you will easily be able to fly with these packs which is a bonus.
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This is a project I started for my old venture because there are almost no solutions. At that time I didn’t believe the market I was currently in was large enough to warrant putting all the effort in. The first thought was to run off the shelf drill packs in series and use one of those multi pack charging stands to charge them. That would make it a pretty slick system. Only thing is that drill packs don’t supply enough current.
If there is genuinely interest in this I can pick up where I left off. Coincidently the manufacturer I was talking with mailed me on thursday to see how things were going.
The drill packs just help with transporting the cells. Other than that I wouldn’t try to interconnect them at all. I would rather transfer the cells into a unit designed for purpose.
The ultimate setup would be to design a set of modules that could easily be transported by air. In the UK there is the unique challenge that they limit you to 2 spare batteries. But ultimately you could have 4 devices with 2 spare batteries each (that would give you 12 batteries). The camera guys travel like this…
Agreed on the drill packs. The argument for would be that they are relatively cheap off the shelf in volume.
A dedicated pack is ‘easy enough’ to do. The approach we took earlier was a higher C rating and keeping the packs under 100wh. Included in the kit would be 3 modules and a cable for connecting (or we would have integrated the wiring that would be in the cable into the product). Each module has it’s own low voltage cutoff, temp check, current check and balancing and each module gets it’s own charger (that was cheaper and easier than a single charger that charged all at once + safer). Clear markings kn the housing for voltage, capacity and general rules for lipo’s on flight (for those pesky safety check guys). For that application we needed an 18s pack and capacity was less important.
LIFT suggest a solution:
3500€ it is very cheap 
That’s the battery cost. The case for the battery is only $500. But then again I don’t think an airline will let you fly with it…
I don’t think so either. Regardless of packaging it’s still a hassle and only allowed on cargo planes if at all. But if it works it works. For the diyer you could have a ‘flyable’ pack for 500 ish all together.
I’ve seen other projects using the EGO line of batteries. They come in various sizes.
Thanks @MalibuFunHouse, seems like these guys put their “TM” into the URL which breaks the link for me.
… but I google found it. Nice 14S packs but above the 100Wh flight limit, also for the smallest one. Interesting to read that their individual cells are wrapped in a phase-change material that is activated electrically when the battery reaches a certain temperature to turn liquid and draw heat out of the cells.
finally we have it ready…
We optimised our system to very low power consumption and used conventional power Tool battery that most airlines allow to carry in the handbag (LiIon packs<100Wh).
Now finally with this setup you are able to ride for 20minutes with 160€ battery investment or 40minutes with 320€battery budget and as it all fits in a big Samsonite luggage, it is the first inflatable efoil kit that you can legally carry by plane to maldives, Seychelles &Co.
We think that is fair enough and with our infatable system & Carbonfibre box all up weight is only 21kg. This improoves handling by 100% compared to the efoils on the market with more than 35kg…
So now that you know it is possible to foil with those tool battery packs (available around the corner, go for it and build your own;-)
Video of test run with tool battery packs
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FYI, FAA regulation is 100 Wh pack, Not sure if you carry multiple
I travel alot with the drone.
2 packs in the hand language and 1 pack inside the device itself are allowed.
If you have more they are allowed to take it.
Actually thats not true. Some governing bodies allow you to travel with more than 2 spare packs. And then there’s the case where you have have multiple drone and are allowed 2 spare per drone. I have traveled with up to 10 packs before.
Yes it depends on airlines. 100Wh per battery is the limit what most airlines allow. F.e. most european airlines allow up to 10 spare batteries with not more than 100Wh in carry on bagagge without approval.
Today play for my kid bike , Sunday ( store closed sunny ) had to improvise : 4ah 18v x2 so 36v pulling 900w we me on it …
Working nice
Not sure their bms would hold +4c but yes
Now airtravel with inflatable efoil is no limit anymore 