Battery Specialists - Maximize Your Battery Life
Expert battery diagnostics, repairs, rebuilds & custom builds for escooters and eBikes
Call 0468 156 683We specialize in electric scooter and eBike battery repairs
Battery drains quickly? We test and repair faulty cells to restore capacity.
Battery not charging? We diagnose BMS, charger, and connection issues.
Not going as far? We test capacity and rebuild batteries for better performance.
BMS error codes? We diagnose and repair battery management system issues.
We specialize in electric vehicle batteries. Deep knowledge of lithium-ion battery systems.
We use quality branded cells for rebuilds. No cheap knockoffs.
Need more range? We can build custom battery packs to your specifications.
Our diagnostic process explained
We don't guess when it comes to battery problems — we test properly. Here's what our battery diagnostic process involves:
The first thing we do is check the voltage of individual cell groups within your battery pack. A healthy battery should have balanced cell voltages — if one group is significantly lower than the others, that's a red flag. We use a multimeter to measure each parallel group's voltage. For example, in a 10S4P battery (10 groups in series, 4 cells in parallel per group), we check all 10 groups. If we find one group sitting at 3.2V while the others are at 3.7V, we've identified a weak group. This tells us whether the problem is isolated to specific cells or if the whole pack is degraded.
Voltage testing tells us part of the story, but capacity testing under load reveals the true health of the battery. We use a battery analyzer that discharges the battery at a controlled rate (simulating real-world use) and measures how much energy it can deliver. A battery rated for 10Ah (amp-hours) should deliver close to that when new. If we test it and it only delivers 6Ah, the battery has degraded to 60% capacity. This test takes time (several hours) but gives us accurate data. We also monitor voltage sag under load — a healthy battery maintains voltage well under load, while a degraded battery's voltage drops sharply when you draw current. This is why your scooter or eBike cuts out on hills even though the battery shows charge remaining.
The BMS (Battery Management System) is the brain of your battery pack. It monitors cell voltages, controls charging, and protects against over-discharge, over-current, and short circuits. If the BMS fails, your battery won't charge, won't discharge, or might not work at all. We test the BMS by checking if it's allowing charge and discharge, measuring the current limits, and verifying that it's balancing cells properly. Sometimes a BMS goes into protection mode and can be reset. Other times the BMS has failed and needs replacement. We've seen BMS failures from water damage, physical shock, and component failure. Replacing a BMS is often cheaper than replacing the whole battery, but it requires soldering skills and knowing the correct BMS specifications for your battery.
Heat is a sign of trouble in battery packs. During testing, we monitor the temperature of the battery during charging and discharging. A battery that gets unusually hot has high internal resistance (a sign of degradation) or a short circuit somewhere. We use an infrared thermometer to check for hot spots on the battery case. If one area is significantly hotter than the rest, there's likely a problem in that cell group — maybe a damaged cell with high resistance, or a poor connection. Thermal runaway (where a damaged cell overheats and potentially catches fire) is rare but serious, so we take temperature monitoring seriously. If your battery has been getting hot during use or charging, that's a strong indicator of a problem that needs diagnosing.
Honest cost comparison and advice
A battery rebuild involves opening your existing battery case, removing the old cells, and installing fresh cells (usually high-quality Samsung or LG 18650 or 21700 cells). You keep the original BMS and case. Rebuilds make sense when: (1) Your battery case is in good condition and can be opened without destroying it. (2) The BMS is still functioning correctly. (3) The cost of a rebuild is significantly less than a new OEM battery. (4) You want to upgrade capacity — we can often fit higher-capacity cells in the same case. For example, an OEM Bosch eBike battery might cost $900-$1200 new. A rebuild with quality Samsung cells might cost $450-$650 — half the price. For scooter batteries, OEM replacements are often $300-$600, while a rebuild might be $200-$400. The catch is that not all batteries can be rebuilt. Some are glued shut or use proprietary BMS systems that we can't source replacements for. We assess each battery individually and give you honest advice.
Sometimes buying a new battery is the smarter option. This is true when: (1) The battery case is damaged or sealed in a way that can't be opened without destruction. (2) The BMS has failed and a replacement BMS isn't available or would cost as much as a new battery. (3) You can source a quality replacement battery for a reasonable price. (4) You want the peace of mind of a warranty (new batteries usually come with 6-12 month warranties, rebuilds typically have 3-6 months). Generic replacement batteries for common scooters (Xiaomi, Ninebot) are readily available from $250-$500 depending on capacity. For eBikes, it depends on the brand — generic replacement batteries exist for many models, but brand-name systems like Bosch, Shimano, and Specialized often require OEM batteries. We'll always tell you what's available and what makes financial sense. There's no point spending $500 on a rebuild if a new battery costs $550.
Battery rebuilds aren't quick — they take time and skill. Here's the process: (1) Disassemble the battery case carefully without damaging the BMS or case. (2) Disconnect and remove the old cells, making note of the wiring configuration. (3) Test the BMS to confirm it's working. (4) Assemble the new cells in the correct configuration (series and parallel groups) using nickel strip and spot welding. (5) Connect the new cell pack to the BMS, ensuring correct polarity and balance wiring. (6) Test the rebuilt battery thoroughly — voltage check, charge/discharge test, BMS function test. (7) Reassemble the case and seal it properly. The process typically takes 3-7 days depending on parts availability and our workload. We use quality cells (Samsung 35E, Samsung 50G, LG MJ1, etc.) because cheap cells aren't worth the labor involved. After the rebuild, you get a battery that performs like new at roughly half the cost of OEM replacement.
Tailored battery packs for your specific needs
Sometimes you need a battery that doesn't exist off-the-shelf. Maybe you want more range than the manufacturer offers, or you need a battery to fit a unique space, or you're building a custom eBike or scooter from scratch. That's where custom battery builds come in.
There are several reasons to go custom: (1) More range — You can't buy a 20Ah battery for your scooter but we can build one. More capacity means more range without changing anything else. (2) Higher voltage — Upgrading from 36V to 48V (or 48V to 52V) gives you more power and speed, but requires a battery with more cells in series. (3) Unique size or shape — Maybe you're building a cargo eBike and need a battery that fits in a custom box, or you're building an off-road scooter and need a ruggedized battery pack. (4) Specific performance requirements — High-drain applications (performance scooters, eBike racing) need batteries built with high-discharge cells. Custom builds let us optimize for your use case. (5) DIY projects — If you're building your own eBike conversion or electric vehicle, you need a battery pack designed for your motor and controller specs.
Building a custom battery starts with understanding your requirements. We'll ask: What voltage does your system need? What capacity (Ah) do you want? What are the size constraints? What kind of discharge current will you be pulling? What's your budget? Based on this, we design the battery pack — determining the cell configuration (series and parallel groups), selecting the appropriate cells (we use quality Samsung, LG, or Panasonic cells), and choosing a BMS with the correct voltage rating and current limits. Then we build it: spot-welding nickel strips to create the cell pack, wiring the BMS with balance leads and main power connections, adding protective padding and insulation, and housing it in a case (we can use a hard plastic case, soft pack, or custom enclosure). Finally, we test the completed pack thoroughly before handing it over. Custom builds typically cost more than off-the-shelf batteries due to the labor involved, but you get exactly what you need.
We've built custom batteries for various applications: A 52V 20Ah battery for a high-performance scooter (Kaabo Wolf Warrior) that wanted extended range beyond the stock battery. A 48V 15Ah battery for a DIY eBike conversion using a Bafang mid-drive motor, built to fit in a custom triangle bag. A 36V 30Ah battery for a cargo eBike that hauls heavy loads and needed maximum range. A 24V 10Ah battery for a mobility scooter rebuild where the original battery was discontinued. A dual-battery setup for a long-distance commuter eBike, wired in parallel for double the range. If you've got a project that needs a custom battery solution, we can build it — but we'll also tell you honestly if an off-the-shelf option would work just as well for less money.
