downtube electronics

downtube electronics.md

I've now thoroughly reviewed both PDFs. Let me give you a clear summary.

USB Charging & Battery Protection: Already in the Design

Yes, both USB charging and battery protection are already covered in your battery architecture — they're part of the self-contained battery pack design you've been developing. Here's the breakdown:

USB-C Charging ✅

The battery pack includes a full USB-C PD charging system built into the electronics bay at the bottom of the scaffold: ppl-ai-file-upload.s3.amazonaws

• USB-C panel-mount port (IP67, on the side of the battery end cap)
• PD trigger board (ZY12PDN or STUSB4531, ~31×15×4mm) — negotiates 20V from any charger 45W–240W automatically
• Boost converter (XL6019, 20V→42V CC/CV) — steps up to pack charge voltage
• Total electronics fit in ~60×45×25mm, tucked into the electronics bay

The key design point: all electronics live on the battery, not in the frame. You pull the battery out, plug your MacBook charger into the USB-C port on the side, charge on the kitchen table. The frame side is 100% passive — just flat copper pads. ppl-ai-file-upload.s3.amazonaws

Battery Protection (BMS) ✅

A 10S BMS is included in the electronics bay, handling: ppl-ai-file-upload.s3.amazonaws

• Overcurrent, overvoltage, undervoltage protection
• Short-circuit and temperature cutoff
• Cell balancing during charge
• Per-cell fusing was deliberately skipped — at 3.5A per cell in 2P, the BMS alone handles everything adequately

Battery-to-Frame Connector ✅

The connector design settled on an elevated pad island + recessed pogo pin dock approach: ppl-ai-file-upload.s3.amazonaws

• Frame side: Elevated flat gold pads on a raised "speed bump" — water sheets off, no pooling
• Battery side: 6-pin pogo block recessed deep inside a dock cavity — finger-safe by geometry (IP2X-style)
• 2 power pins + signal/thermistor/comm pins

---

Downtube Oval Size: ~50×65 Is Flexible

Your notes confirm the DT dimensions are not locked down yet, and you've been exploring both round and oval options: ppl-ai-file-upload.s3.amazonaws

Discussed Size	Context
50mm round	Original spec for 2×2 grid of 21700 cells
55–60mm	Referenced for fitting 21700s with BMS/wiring room
43×59mm oval	The 1-2-1 diamond layout (narrower, taller)
~50×65 (your current thinking)	Wider than the diamond, gives more lateral room

The 50×65 oval gives you more cross-sectional area than the 43×59 diamond and better lateral stiffness for pedaling loads. The tall axis (65mm) resists braking/vertical loads while the narrow axis (50mm) keeps the frame slim between your knees. Since you're building in aluminum (not steel), you have freedom to specify custom oval tubing from the fabricator. ppl-ai-file-upload.s3.amazonaws

The scaffold cage parameters (currently cagew = 53, cageh = 48 in the OpenSCAD file) would need updating to match whatever oval you settle on. With a 50×65 outer and ~2mm wall, you'd have roughly 46×61mm inner bore — plenty of room for the 2×2 cell grid (~43×43mm footprint) plus wiring channel and air gaps. ppl-ai-file-upload.s3.amazonaws

Bottom line: your electronics stack is already specced and costed at $22–38 total for BMS + USB-C PD + boost converter. The DT oval just needs to be finalized around whatever gives comfortable clearance for the scaffold + 1mm air gap on each side. ppl-ai-file-upload.s3.amazonaws

Option | Cross-section | KT compatible | Price | Verdict -- | -- | -- | -- | --

Your custom scaffold build remains the only route that fits your DT and works with the KT controller. The generic market simply doesn't manufacture a cased intube pack slim enough for eRoad/eGravel tubes — that niche is entirely dominated by OEM-integrated systems (Bafang, Shimano, Bosch) using proprietary extrusions and protocols.

Now I have a comprehensive picture. Let me compile the key findings into a clear, practical answer.

Here's what the generic/aftermarket intube battery market actually looks like for your use case:

The Generic Intube Battery Landscape

The short summary: the truly slim intube form factor (sub-55mm cross-section) barely exists in the generic/Alibaba market. Everything you find splits into two different product categories that don't map cleanly onto your frame.

---

What "Intube" Actually Means on Alibaba

Most listings labelled "intube" or "hidden tube" are not slim eRoad-style batteries. They fall into a few real categories:

Type	Cross-section	Example	Controller compat
HIMO C30 style	59 × 72 mm	Alibaba HIMO C30 OEM, ~$133 [alibaba](https://www.alibaba.com/product-detail/HIMO-C30-Ebike-Hidden-Tube-Battery_1600722882171.html)	Yes — standard 2-wire DC out [alibaba](https://www.alibaba.com/product-detail/HIMO-C30-Ebike-Hidden-Tube-Battery_1600722882171.html)
Reention Rhino IR-5	60.1 × 96.3 mm	Reention / OEM Rhino IR-5 reention	Yes — standard connector reention
Reention Rhino IR-7/21700	~85 × 108 mm	IR-21700, 441 mm long forums.electricbikereview	Yes
GreenBikeKit "mini"	Customized — no fixed dims	GBK 36V 10–25Ah, cells only greenbikekit	Yes — bare cell pack with BMS
Yose Power/LLobe style	99 × 40.6 mm	36V 11.6Ah, 375.5 mm yosepower	Yes

None of these come close to 48.5 × 48.5 mm. The narrowest confirmed generic intube is the Yose Power style at 40.6 mm in one direction — but it's 99 mm wide, making it a flat slab, not a square tube pack. yosepower

---

GreenBikeKit Specifically

GBK's "36V mini compact" product is not a finished intube pack — it's a custom cell assembly service: you specify dimensions, they build a naked pack (no case) around 21700-50G or 18650-35E cells with a 10S BMS. The listed weight is ~2.25 kg for 10S2P, which confirms 21700 cells. This is essentially the same service you'd be doing yourself with Samsung 50E cells — just outsourced to China and shipped. The GBK offering doesn't include a case, which means you still need to build the scaffold/holder yourself, and the BMS output is standard two-wire 36V DC (no proprietary handshake). greenbikekit

Price from GBK: roughly $80–120 shipped for a 10S2P 21700 naked pack based on their product tier. Your DIY build with 20× Samsung 50E likely costs less per Wh and gives you control over cell selection.

---

The HIMO C30 OEM Pack — Closest Ready-Made Option

The HIMO C30 replacement battery is the most interesting find: it's a 36V 10Ah 21700 10S2P intube pack sold as a generic OEM replacement on Alibaba for ~$133. Dimensions are 59 × 72 × 386 mm (or 434 mm in the longer variant). It uses a standard DC output connector — no CANBus, no handshake — fully compatible with KT controllers. alibaba

The catch: 59 × 72 mm is too wide for your 65 × 55 mm DT on the 72 mm axis. It would clear 65 mm but not 55 mm. So it's a miss dimensionally, even though it ticks every other box.

---

The Fundamental Problem

The physics are the issue. A 10S2P pack with 21700 cells (21 mm diameter) in a 2P configuration always needs at minimum:

• 2 cells side by side = 42 mm + cell spacing + insulation + case wall ≈ 48–52 mm minimum per axis
• A square cross-section (like the Bafang F040's 48.5 × 48.5) is the theoretical minimum for 21700 2P
• Any commercial pack adds a plastic/aluminum housing over this, pushing dimensions to 55–75 mm

This is exactly why no generic manufacturer builds a sub-55 mm intube pack — the cell geometry doesn't leave room for a meaningful production casing at that size. Bafang achieves 48.5 × 48.5 mm by using a precision-extruded aluminum rail system as the structural element, eliminating a separate outer case entirely. greenbikekit

---

Practical Verdict for Your Build

Option	Cross-section	KT compatible	Price	Verdict
GBK custom naked pack	Your spec	✅ Yes	~$100	Same as DIY, no case
HIMO C30 OEM	59 × 72 mm	✅ Yes	~$133 alibaba	Too wide (72 mm)
Reention Rhino IR-5	60 × 96 mm	✅ Yes	~$103–171 alibaba	Far too wide
Your 10S2P Samsung 50E scaffold	65 × 55 mm	✅ Yes	~$80–100 cells only	Best fit
Bafang F040	48.5 × 48.5 mm	❌ BMS lock	~€400+ OEM	Firmware-locked

Your custom scaffold build remains the only route that fits your DT and works with the KT controller. The generic market simply doesn't manufacture a cased intube pack slim enough for eRoad/eGravel tubes — that niche is entirely dominated by OEM-integrated systems (Bafang, Shimano, Bosch) using proprietary extrusions and protocols.

No, you don't need to build a separate shell. Your aluminum downtube IS the shell. You just need a few cheap layers between the bare pack and the tube wall.

What Goes Between Pack and Tube

Layer | Material | Purpose | Thickness -- | -- | -- | -- Electrical insulation | Fish paper or Kapton sheet | Prevents cell terminals from shorting against aluminum DT | 0.2–0.5mm Vibration damping | EVA foam or neoprene wrap | Stops rattling, absorbs road vibration | 2–3mm [tamobykesport]​[youtube]​ Thermal path | Thermal pad (optional) | Conducts cell heat to the aluminum DT for passive cooling | 1mm [letrigo]​

That's it. The GreenBikeKit bare pack already comes in heat-shrink wrap, which provides basic electrical insulation. You wrap 2–3mm of EVA foam around it, slide it into the DT, and the foam compression keeps it snug and rattle-free.reddit+1

Why This Works

• The aluminum DT is your outer shell — it's stronger, more impact-resistant, and more thermally conductive than any plastic battery case[letrigo]​

• The DT provides IP-level water protection by design — sealed ends with grommets at the cable entry points

• Premium commercial batteries use exactly this philosophy internally: rigid outer shell → elastic damping layer → cells. They call it "rigid-outside, flexible-inside". Your DT is the rigid outside, the foam is the flexible inside[gebbattery]​

• The aluminum frame actually doubles as a heat sink, passively cooling the pack through the tube wall during hot summer rides[letrigo]​

Securing the Pack

The bare pack needs to not slide around lengthwise inside the tube. Two options:

• Foam friction fit — if the foam wrap is sized correctly, the pack press-fits and stays put from friction alone[reddit]​

• End stops — your electronics module on one end and a simple 3D-printed bulkhead on the other end sandwich the pack in place. The pack physically can't move.

So the total "shell" is: €2 of foam + €0.50 of fish paper + your existing DT. No custom housing, no injection mold, no extra weight. The tube you already designed is the enclosure.

No, you don't need to build a separate shell. **Your aluminum downtube IS the shell.** You just need a few cheap layers between the bare pack and the tube wall.

What Goes Between Pack and Tube

Layer	Material	Purpose	Thickness
Electrical insulation	Fish paper or Kapton sheet	Prevents cell terminals from shorting against aluminum DT	0.2–0.5mm
Vibration damping	EVA foam or neoprene wrap	Stops rattling, absorbs road vibration	2–3mm [tamobykesport](https://tamobykesport.com/blogs/blog/diy-e-bike-battery-insulation-projects-maximize-range-in-cold-weather)
Thermal path	Thermal pad (optional)	Conducts cell heat to the aluminum DT for passive cooling	1mm [letrigo](https://letrigo.com/blogs/knowledge/ebike-lithium-battery-cooling-solutions)

That's it. The GreenBikeKit bare pack already comes in heat-shrink wrap, which provides basic electrical insulation. You wrap 2–3mm of EVA foam around it, slide it into the DT, and the foam compression keeps it snug and rattle-free. reddit

Why This Works

• The aluminum DT is your outer shell — it's stronger, more impact-resistant, and more thermally conductive than any plastic battery case [letrigo](https://letrigo.com/blogs/knowledge/ebike-lithium-battery-cooling-solutions)
• The DT provides IP-level water protection by design — sealed ends with grommets at the cable entry points
• Premium commercial batteries use exactly this philosophy internally: rigid outer shell → elastic damping layer → cells. They call it "rigid-outside, flexible-inside". Your DT is the rigid outside, the foam is the flexible inside [gebbattery](https://www.gebbattery.com/news/waterproof-and-shockproof-design-in-modern-e-b-85280390.html)
• The aluminum frame actually doubles as a heat sink, passively cooling the pack through the tube wall during hot summer rides [letrigo](https://letrigo.com/blogs/knowledge/ebike-lithium-battery-cooling-solutions)

Securing the Pack

The bare pack needs to not slide around lengthwise inside the tube. Two options:

• Foam friction fit — if the foam wrap is sized correctly, the pack press-fits and stays put from friction alone [reddit](https://www.reddit.com/r/ebikes/comments/16fhfs0/what_setup_do_i_need_for_an_aftermarket_second/)
• End stops — your electronics module on one end and a simple 3D-printed bulkhead on the other end sandwich the pack in place. The pack physically can't move.

So the total "shell" is: €2 of foam + €0.50 of fish paper + your existing DT. No custom housing, no injection mold, no extra weight. The tube you already designed is the enclosure.

I now have a very clear picture. The Aventon Soltera OEM pack dimensions are confirmed at 386 × 60 × 72 mm, and the Green Cell 90 × 90 mm cross-section is another data point. This is a really sharp strategic pivot — let me lay it out properly.alibaba+1

---

The Round-Tube Strategy: Sound Engineering Logic

This is a genuinely good reframe. You're proposing to design the frame around a commodity battery rather than designing a battery around the frame — which inverts your risk profile entirely. Here's the full picture:

---

What the Aventon Soltera OEM Pack Actually Is

The Alibaba listing confirms: 386 × 60 × 72 mm, 21700 cells, 36V 10Ah (360 Wh), standard BMS with no proprietary handshake. It's one of dozens of functionally identical packs from Chinese OEM houses — the "Aventon Soltera" label is just whatever bike brand ordered that run. The underlying pack is a generic 60 × 72 mm rectangular cross-section intube battery with a round end cap for aesthetic closure.[alibaba]​

This is the dominant form factor in the generic OEM intube world. Most packs cluster around 60–90 mm on the wide axis, with a rectangular (not round) cross-section inside a round-ended enclosure. The round covers you're noticing are cosmetic — the battery body itself is rectangular, designed to slide into a D-shaped or oval tube, not a true circle.greencell+1

---

Standard Cross-Sections in the Generic Market

Pack type | Cross-section | Example -- | -- | -- Aventon Soltera OEM | 60 × 72 mm | ~$115–160, Alibaba [alibaba]​ Green Cell 90-series | 90 × 90 mm | 367 × 90 × 90 mm, 36V 13Ah [greencell]​ Bosch PowerTube clone | 83.7 × 65 mm | 426.5 × 83.7 × 65 mm [ebike24]​ Yamaha intube | 84 × 72 mm | 385 × 84 × 72 mm [ebike24]​ CycMotor A-65 | ~65 mm wide | Side-slide, CNC alu case [cycmotor]​

---

The Real Unlock: Serviceability + Certification

The strongest argument for your pivot is CE/UN38.3 certification. A generic OEM pack already carries it. Building your own 10S2P scaffold means you become the battery manufacturer for liability purposes under EU regulations — that's a significant compliance burden for a small brand. Sourcing a certified pack transfers that liability to the supplier and simplifies your CE declaration for the whole bike.[alibaba]​

The round tube at ~95–100 mm OD is a legitimate trade-off for a trekking, urban, or cargo-influenced frame — less so for an eRoad/eGravel position. If your target is a more upright city/commuter/adventure geometry, a bold large-diameter downtube is actually on-trend (see Specialized Turbo Vado, Canyon Pathlite). If you're targeting road-race aesthetics, it's a harder sell.[cycmotor]​

I now have a very clear picture. The Aventon Soltera OEM pack dimensions are confirmed at **386 × 60 × 72 mm**, and the Green Cell 90 × 90 mm cross-section is another data point. This is a really sharp strategic pivot — let me lay it out properly. [alibaba](https://www.alibaba.com/product-detail/Aventon-Soltera-Ebike-Frame-Intube-Batteries_1601384124500.html)

---

The Round-Tube Strategy: Sound Engineering Logic

This is a genuinely good reframe. You're proposing to design the frame around a commodity battery rather than designing a battery around the frame — which inverts your risk profile entirely. Here's the full picture:

---

What the Aventon Soltera OEM Pack Actually Is

The Alibaba listing confirms: 386 × 60 × 72 mm, 21700 cells, 36V 10Ah (360 Wh), standard BMS with no proprietary handshake. It's one of dozens of functionally identical packs from Chinese OEM houses — the "Aventon Soltera" label is just whatever bike brand ordered that run. The underlying pack is a generic 60 × 72 mm rectangular cross-section intube battery with a round end cap for aesthetic closure. [alibaba](https://www.alibaba.com/product-detail/Aventon-Soltera-Ebike-Frame-Intube-Batteries_1601384124500.html)

This is the dominant form factor in the generic OEM intube world. Most packs cluster around 60–90 mm on the wide axis, with a rectangular (not round) cross-section inside a round-ended enclosure. The round covers you're noticing are cosmetic — the battery body itself is rectangular, designed to slide into a D-shaped or oval tube, not a true circle. greencell

---

Standard Cross-Sections in the Generic Market

Pack type	Cross-section	Example
Aventon Soltera OEM	60 × 72 mm	~$115–160, Alibaba [alibaba](https://www.alibaba.com/product-detail/Aventon-Soltera-Ebike-Frame-Intube-Batteries_1601384124500.html)
Green Cell 90-series	90 × 90 mm	367 × 90 × 90 mm, 36V 13Ah [greencell](https://greencell.global/en/e-bike-batteries/4429-green-cell-e-bike-battery-36v-13ah-468wh-down-tube-ebike-ec5-for-ancheer-samebike-fafrees-with-charger.html)
Bosch PowerTube clone	83.7 × 65 mm	426.5 × 83.7 × 65 mm [ebike24](https://www.ebike24.com/ebike-vision-powerpack-intube-battery-640-wh-bosch-powertube-alternative)
Yamaha intube	84 × 72 mm	385 × 84 × 72 mm [ebike24](https://www.ebike24.com/yamaha-intube-battery-630wh)
CycMotor A-65	~65 mm wide	Side-slide, CNC alu case [cycmotor](https://www.cycmotor.com/a-65-battery)

The 60 × 72 mm family (Aventon/HIMO-type) is the slimmest widely available generic. If you round up to fit a true circle, that cross-section demands a minimum ~93 mm diameter tube (diagonal of 60 × 72 = 93.6 mm). That's a large downtube by any road/gravel standard.

---

Round Tube Sizing Reality

To fit a 60 × 72 mm rectangular pack inside a round tube with clearance for the slide-rail and any tolerance, you'd need:

• Inner diameter ≥ 94 mm (diagonal clearance)
• Wall thickness ~2–2.5 mm for 6061 aluminum
• Outer diameter ≈ 98–100 mm

That's essentially a 100mm OD round downtube — which is larger than most modern gravel/road bike downtubes (typically 40–60 mm OD) and getting into fat-bike or cargo territory. The CycMotor A-65 side-slide system (fits "most bikes") works around this by ejecting sideways rather than end-to-end, which tolerates a narrower tube. [cycmotor](https://www.cycmotor.com/a-65-battery)

---

The Strategic Trade-off

Aspect	Round tube + generic pack	Custom scaffold (your original plan)
Battery sourcing	✅ Drop-in OEM, ~$100–160 [alibaba](https://www.alibaba.com/product-detail/Aventon-Soltera-Ebike-Frame-Intube-Batteries_1601384124500.html)	✅ ~$80–100 cells only
Dock/locking	✅ Included with pack	🔧 You design it
Frame tube OD	⚠️ ~95–100 mm round (bulky)	✅ 65 × 55 mm elliptical (svelte)
Frame aesthetics	⚠️ Chunky, cargo-bike vibe	✅ Road/gravel look
Engineering effort	✅ Battery done — focus on frame	🔧 Battery + frame both custom
Replaceability	✅ Customer can swap standard pack	❌ Proprietary to your scaffold
Regulatory/CE	✅ Pack comes CE-certified [alibaba](https://www.alibaba.com/product-detail/Aventon-Soltera-Ebike-Frame-Intube-Batteries_1601384124500.html)	🔧 You certify the whole assembly

---

The Real Unlock: Serviceability + Certification

The strongest argument for your pivot is CE/UN38.3 certification. A generic OEM pack already carries it. Building your own 10S2P scaffold means you become the battery manufacturer for liability purposes under EU regulations — that's a significant compliance burden for a small brand. Sourcing a certified pack transfers that liability to the supplier and simplifies your CE declaration for the whole bike. [alibaba](https://www.alibaba.com/product-detail/Aventon-Soltera-Ebike-Frame-Intube-Batteries_1601384124500.html)

The round tube at ~95–100 mm OD is a legitimate trade-off for a trekking, urban, or cargo-influenced frame — less so for an eRoad/eGravel position. If your target is a more upright city/commuter/adventure geometry, a bold large-diameter downtube is actually on-trend (see Specialized Turbo Vado, Canyon Pathlite). If you're targeting road-race aesthetics, it's a harder sell. [cycmotor](https://www.cycmotor.com/a-65-battery)

I now have a very clear picture. The Aventon Soltera OEM pack dimensions are confirmed at 386 × 60 × 72 mm, and the Green Cell 90 × 90 mm cross-section is another data point. This is a really sharp strategic pivot — let me lay it out properly.alibaba+1

---

The Round-Tube Strategy: Sound Engineering Logic

This is a genuinely good reframe. You're proposing to design the frame around a commodity battery rather than designing a battery around the frame — which inverts your risk profile entirely. Here's the full picture:

---

What the Aventon Soltera OEM Pack Actually Is

The Alibaba listing confirms: 386 × 60 × 72 mm, 21700 cells, 36V 10Ah (360 Wh), standard BMS with no proprietary handshake. It's one of dozens of functionally identical packs from Chinese OEM houses — the "Aventon Soltera" label is just whatever bike brand ordered that run. The underlying pack is a generic 60 × 72 mm rectangular cross-section intube battery with a round end cap for aesthetic closure.[alibaba]​

This is the dominant form factor in the generic OEM intube world. Most packs cluster around 60–90 mm on the wide axis, with a rectangular (not round) cross-section inside a round-ended enclosure. The round covers you're noticing are cosmetic — the battery body itself is rectangular, designed to slide into a D-shaped or oval tube, not a true circle.greencell+1

---

Standard Cross-Sections in the Generic Market

Pack type | Cross-section | Example -- | -- | -- Aventon Soltera OEM | 60 × 72 mm | ~$115–160, Alibaba [alibaba]​ Green Cell 90-series | 90 × 90 mm | 367 × 90 × 90 mm, 36V 13Ah [greencell]​ Bosch PowerTube clone | 83.7 × 65 mm | 426.5 × 83.7 × 65 mm [ebike24]​ Yamaha intube | 84 × 72 mm | 385 × 84 × 72 mm [ebike24]​ CycMotor A-65 | ~65 mm wide | Side-slide, CNC alu case [cycmotor]​

---

The Real Unlock: Serviceability + Certification

The strongest argument for your pivot is CE/UN38.3 certification. A generic OEM pack already carries it. Building your own 10S2P scaffold means you become the battery manufacturer for liability purposes under EU regulations — that's a significant compliance burden for a small brand. Sourcing a certified pack transfers that liability to the supplier and simplifies your CE declaration for the whole bike.[alibaba]​

The round tube at ~95–100 mm OD is a legitimate trade-off for a trekking, urban, or cargo-influenced frame — less so for an eRoad/eGravel position. If your target is a more upright city/commuter/adventure geometry, a bold large-diameter downtube is actually on-trend (see Specialized Turbo Vado, Canyon Pathlite). If you're targeting road-race aesthetics, it's a harder sell.[cycmotor]​

I now have a very clear picture. The Aventon Soltera OEM pack dimensions are confirmed at **386 × 60 × 72 mm**, and the Green Cell 90 × 90 mm cross-section is another data point. This is a really sharp strategic pivot — let me lay it out properly. [alibaba](https://www.alibaba.com/product-detail/Aventon-Soltera-Ebike-Frame-Intube-Batteries_1601384124500.html)

---

The Round-Tube Strategy: Sound Engineering Logic

This is a genuinely good reframe. You're proposing to design the frame around a commodity battery rather than designing a battery around the frame — which inverts your risk profile entirely. Here's the full picture:

---

What the Aventon Soltera OEM Pack Actually Is

The Alibaba listing confirms: 386 × 60 × 72 mm, 21700 cells, 36V 10Ah (360 Wh), standard BMS with no proprietary handshake. It's one of dozens of functionally identical packs from Chinese OEM houses — the "Aventon Soltera" label is just whatever bike brand ordered that run. The underlying pack is a generic 60 × 72 mm rectangular cross-section intube battery with a round end cap for aesthetic closure. [alibaba](https://www.alibaba.com/product-detail/Aventon-Soltera-Ebike-Frame-Intube-Batteries_1601384124500.html)

This is the dominant form factor in the generic OEM intube world. Most packs cluster around 60–90 mm on the wide axis, with a rectangular (not round) cross-section inside a round-ended enclosure. The round covers you're noticing are cosmetic — the battery body itself is rectangular, designed to slide into a D-shaped or oval tube, not a true circle. greencell

---

Standard Cross-Sections in the Generic Market

Pack type	Cross-section	Example
Aventon Soltera OEM	60 × 72 mm	~$115–160, Alibaba [alibaba](https://www.alibaba.com/product-detail/Aventon-Soltera-Ebike-Frame-Intube-Batteries_1601384124500.html)
Green Cell 90-series	90 × 90 mm	367 × 90 × 90 mm, 36V 13Ah [greencell](https://greencell.global/en/e-bike-batteries/4429-green-cell-e-bike-battery-36v-13ah-468wh-down-tube-ebike-ec5-for-ancheer-samebike-fafrees-with-charger.html)
Bosch PowerTube clone	83.7 × 65 mm	426.5 × 83.7 × 65 mm [ebike24](https://www.ebike24.com/ebike-vision-powerpack-intube-battery-640-wh-bosch-powertube-alternative)
Yamaha intube	84 × 72 mm	385 × 84 × 72 mm [ebike24](https://www.ebike24.com/yamaha-intube-battery-630wh)
CycMotor A-65	~65 mm wide	Side-slide, CNC alu case [cycmotor](https://www.cycmotor.com/a-65-battery)

The 60 × 72 mm family (Aventon/HIMO-type) is the slimmest widely available generic. If you round up to fit a true circle, that cross-section demands a minimum ~93 mm diameter tube (diagonal of 60 × 72 = 93.6 mm). That's a large downtube by any road/gravel standard.

---

Round Tube Sizing Reality

To fit a 60 × 72 mm rectangular pack inside a round tube with clearance for the slide-rail and any tolerance, you'd need:

• Inner diameter ≥ 94 mm (diagonal clearance)
• Wall thickness ~2–2.5 mm for 6061 aluminum
• Outer diameter ≈ 98–100 mm

That's essentially a 100mm OD round downtube — which is larger than most modern gravel/road bike downtubes (typically 40–60 mm OD) and getting into fat-bike or cargo territory. The CycMotor A-65 side-slide system (fits "most bikes") works around this by ejecting sideways rather than end-to-end, which tolerates a narrower tube. [cycmotor](https://www.cycmotor.com/a-65-battery)

---

The Strategic Trade-off

Aspect	Round tube + generic pack	Custom scaffold (your original plan)
Battery sourcing	✅ Drop-in OEM, ~$100–160 [alibaba](https://www.alibaba.com/product-detail/Aventon-Soltera-Ebike-Frame-Intube-Batteries_1601384124500.html)	✅ ~$80–100 cells only
Dock/locking	✅ Included with pack	🔧 You design it
Frame tube OD	⚠️ ~95–100 mm round (bulky)	✅ 65 × 55 mm elliptical (svelte)
Frame aesthetics	⚠️ Chunky, cargo-bike vibe	✅ Road/gravel look
Engineering effort	✅ Battery done — focus on frame	🔧 Battery + frame both custom
Replaceability	✅ Customer can swap standard pack	❌ Proprietary to your scaffold
Regulatory/CE	✅ Pack comes CE-certified [alibaba](https://www.alibaba.com/product-detail/Aventon-Soltera-Ebike-Frame-Intube-Batteries_1601384124500.html)	🔧 You certify the whole assembly

---

The Real Unlock: Serviceability + Certification

The strongest argument for your pivot is CE/UN38.3 certification. A generic OEM pack already carries it. Building your own 10S2P scaffold means you become the battery manufacturer for liability purposes under EU regulations — that's a significant compliance burden for a small brand. Sourcing a certified pack transfers that liability to the supplier and simplifies your CE declaration for the whole bike. [alibaba](https://www.alibaba.com/product-detail/Aventon-Soltera-Ebike-Frame-Intube-Batteries_1601384124500.html)

The round tube at ~95–100 mm OD is a legitimate trade-off for a trekking, urban, or cargo-influenced frame — less so for an eRoad/eGravel position. If your target is a more upright city/commuter/adventure geometry, a bold large-diameter downtube is actually on-trend (see Specialized Turbo Vado, Canyon Pathlite). If you're targeting road-race aesthetics, it's a harder sell. [cycmotor](https://www.cycmotor.com/a-65-battery)

Here's the full landscape. The bad news: nothing slim and round exists off-the-shelf for a track bike DT. The good news: there are clear options for Phase 1.

Every Intube Battery + Dock System Available

Reention (Largest OEM — supplies Aventon, Ride1Up, NCM, etc.)

Model | Cross-section | Length | Type | Cover shape | Fits slim DT? -- | -- | -- | -- | -- | -- Coral FC-4 | ~55mm round | ~200–280mm | Inner tube, removable, key lock | Round end cap | ✅ Slim enough — but very short, ~250Wh max [haidrive.en.made-in-china]​ Penguin | ~60mm round | unknown | Inner tube, folding bike | Round | ⚠️ Possibly — need to confirm from catalogue [reention]​ EEL / EEL Pro | 94 × 64mm | ~350mm | Inner tube, removable | Oval end cap | ❌ 94mm too wide [greenbikekit]​ Dorado ID | 65 × 85mm+ | ~392mm | Inner tube, removable, key lock | Oval | ❌ 85mm too wide [aliexpress]​ Dorado Plus | 75 × 90mm+ | ~400mm+ | Inner tube | Oval | ❌ Too wide [eunorau-ebike]​

Your Best Phase 1 Options

Option A: Reention Coral dock + custom length battery

Contact Reention and ask for a Coral-series dock with a custom longer battery tube — same 55mm round cross-section, but 350–400mm long instead of 200mm. They do custom OEM — it's their entire business. This gives you:reention+1

• Round ~55–58mm DT

• ~360Wh in 10S2P 21700

• Removable with key lock

• Dock welds into your frame

• ~$200–255 sample pricing

Option B: Reention Penguin series

Their 2024–2025 catalogue lists the Penguin as a new inner battery case. I couldn't access the PDF for exact dimensions, but it's listed alongside the Coral as a small-format inner tube battery. Worth requesting specs directly.[reention]​

Option C: GreenBikeKit bare pack + your own simple dock

Skip the commercial dock entirely. GreenBikeKit builds a bare pack to your 55–60mm round spec. You 3D-print or CNC a simple end cap with a 2-pin DC connector + charge port. The battery slides in from one end of the DT and the end cap retains it. No key lock (you use the frame itself as security — the battery can't be removed without tools), but dead simple.[greenbikekit]​

My Recommendation

Option A — Reention Coral custom. Email them your DT inner diameter and desired length. They've built custom variants for dozens of brands already. You get a proven dock + lock + charge port + battery as one tested unit, and you design your round DT to match whatever diameter they come back with. That diameter becomes your frame spec, not the other way around.[ebikebatterypro]​

Want me to draft that inquiry email to Reention?

Here's the full landscape. The bad news: **nothing slim and round exists off-the-shelf for a track bike DT**. The good news: there are clear options for Phase 1.

Every Intube Battery + Dock System Available

Reention (Largest OEM — supplies Aventon, Ride1Up, NCM, etc.)

Model	Cross-section	Length	Type	Cover shape	Fits slim DT?
Coral FC-4	~55mm round	~200–280mm	Inner tube, removable, key lock	Round end cap	✅ Slim enough — but very short, ~250Wh max [haidrive.en.made-in-china](https://haidrive.en.made-in-china.com/product/zQSUhFYbXncj/China-Reention-36V-Coral-FC-4-Battery-Inner-Downtube-Lithium-Ion-Foldable-E-Bike-Battery.html)
Penguin	~60mm round	unknown	Inner tube, folding bike	Round	⚠️ Possibly — need to confirm from catalogue [reention](https://www.reention.com/uploads/soft/240807/2024-2025.pdf)
EEL / EEL Pro	94 × 64mm	~350mm	Inner tube, removable	Oval end cap	❌ 94mm too wide [greenbikekit](https://www.greenbikekit.com/48v-14ah-eel-ebike-battery.html)
Dorado ID	65 × 85mm+	~392mm	Inner tube, removable, key lock	Oval	❌ 85mm too wide [aliexpress](https://www.aliexpress.com/item/1005004532105588.html)
Dorado Plus	75 × 90mm+	~400mm+	Inner tube	Oval	❌ Too wide [eunorau-ebike](https://eunorau-ebike.com/products/eunorau-48v16ah-21ah-reention-dorado-plus-case-fat-awd-fat-hd-max-cargo-battery-compatible-with-eccobike-addmotor-voltbike-civi-m2s-surface604bikes-rambo-quietkat-bikes)

FIT E-Bike (Rotax/BRP system)

Model	Type	Notable feature	Fits slim DT?
FIT BAT Tubepack	Inner tube, removable	FIT Clictake one-handed removal dock	❌ Designed for Rotax motors, proprietary protocol [fit-ebike](https://www.fit-ebike.com/en-en/technology/system/batteries/)

Hailong (External downtube — NOT intube)

All Hailong models are 90 × 90mm minimum — external shark-style packs bolted to the outside of the DT. None fit inside a frame tube. topwellpower

Grin Tech (Canada)

Their downtube packs use a cradle + slide-in system with key lock, but they're also external mounts on waterbottle bosses — 90mm+ cross-section. [ebikes](https://ebikes.ca/amfile/file/download/file/210/product/1013/)

The Gap

What exists	Cross-section	Problem
Proprietary intube (Bosch, Shimano, Bafang)	48–75mm ✅	Firmware locked, won't work with KT
Generic intube (Reention Coral)	~55mm ✅	Only short folding-bike sizes, ~250Wh
Generic intube (Reention EEL/Dorado)	65–94mm	Too wide for a slim track DT
External downtube (Hailong, Grin)	90mm+	Way too fat, external mount

Your Best Phase 1 Options

Option A: Reention Coral dock + custom length battery

Contact Reention and ask for a Coral-series dock with a custom longer battery tube — same 55mm round cross-section, but 350–400mm long instead of 200mm. They do custom OEM — it's their entire business. This gives you: reention

• Round ~55–58mm DT
• ~360Wh in 10S2P 21700
• Removable with key lock
• Dock welds into your frame
• ~$200–255 sample pricing

Option B: Reention Penguin series

Their 2024–2025 catalogue lists the Penguin as a new inner battery case. I couldn't access the PDF for exact dimensions, but it's listed alongside the Coral as a small-format inner tube battery. Worth requesting specs directly. [reention](https://www.reention.com/uploads/soft/240807/2024-2025.pdf)

Option C: GreenBikeKit bare pack + your own simple dock

Skip the commercial dock entirely. GreenBikeKit builds a bare pack to your 55–60mm round spec. You 3D-print or CNC a simple end cap with a 2-pin DC connector + charge port. The battery slides in from one end of the DT and the end cap retains it. No key lock (you use the frame itself as security — the battery can't be removed without tools), but dead simple. [greenbikekit](https://www.greenbikekit.com/36v-ebike-battery-with-mini-size.html)

My Recommendation

Option A — Reention Coral custom. Email them your DT inner diameter and desired length. They've built custom variants for dozens of brands already. You get a proven dock + lock + charge port + battery as one tested unit, and you design your round DT to match whatever diameter they come back with. That diameter becomes your frame spec, not the other way around. [ebikebatterypro](https://ebikebatterypro.com/reention-ebike-battery/)

Want me to draft that inquiry email to Reention?

retention is good. this cleans up our path to market a lot! and we can focus on branding and product position. treat the parts as modular things we source in stead of build our selfs. we focus on how it fits together. economics. sales. product position. building a brand. carving out a new ebike niche

Exactly. This is the shift from being an engineering project to being a product company. You don't build the motor (Bafang), you don't build the battery (Reention), you don't build the lights (LightSKIN), you don't build the controller (KT), you don't build the torque sensor (Bikone). You design how it all comes together — and you own the experience.

What Omera Actually Is Now

You source | You design -- | -- Bafang G020 250W hub motor | Frame geometry + silhouette Reention Coral intube battery + dock | DT diameter to match battery KT controller | Electronics module layout in DT Bikone BB torque sensor | Head tube cable routing LightSKIN H1E handlebar | Plastic antenna top cap LightSKIN SFE-SC seatpost | Paint, finish, graphics Standard headset, fork, cranks, wheels | Brand identity + positioning

The Business Model

This is how every premium brand works:

• Bang & Olufsen doesn't make their own DACs or speaker drivers — they source them. They design the enclosure, the interaction, the feeling.

• Brompton doesn't make their own brakes, shifters, or tires. They design the fold, the ride, the lifestyle.

• Cowboy/VanMoof sourced Bafang motors and generic cells. They sold the app, the look, the brand.[hypeandhyper]​

The difference between a €400 AliExpress e-bike and a €2,500 Omera isn't the bill of materials. It's the curation, the integration, the identity, and the story.

Your Immediate Path

1. Contact Reention — get Coral dock specs + custom battery quote

2. Set DT diameter based on whatever Reention comes back with

3. Model the frame in SCAD — now with a simple round DT, which is actually easier

4. Source everything else — H1E, SFE-SC, G020, KT, Bikone, standard track components

5. Build one prototype — welded frame, all sourced parts bolted on

6. Brand it — name, logo, colorway, photography, website, social

7. Sell the first 10 — pre-orders, Instagram, Oslo cycling community

The engineering is now a bill of materials and an assembly spec, not a multi-year R&D project. The custom battery scaffold, the user-swappable cells, the advanced BMS — that's all Phase 2, when you have revenue, a brand, and customers asking for it.

You just went from building a bike to building a brand. That's the right move.

Exactly. This is the shift from being an **engineering project** to being a **product company**. You don't build the motor (Bafang), you don't build the battery (Reention), you don't build the lights (LightSKIN), you don't build the controller (KT), you don't build the torque sensor (Bikone). You **design how it all comes together** — and you own the experience.

What Omera Actually Is Now

You source	You design
Bafang G020 250W hub motor	Frame geometry + silhouette
Reention Coral intube battery + dock	DT diameter to match battery
KT controller	Electronics module layout in DT
Bikone BB torque sensor	Head tube cable routing
LightSKIN H1E handlebar	Plastic antenna top cap
LightSKIN SFE-SC seatpost	Paint, finish, graphics
Standard headset, fork, cranks, wheels	Brand identity + positioning

The Business Model

This is how every premium brand works:

• Bang & Olufsen doesn't make their own DACs or speaker drivers — they source them. They design the enclosure, the interaction, the feeling.
• Brompton doesn't make their own brakes, shifters, or tires. They design the fold, the ride, the lifestyle.
• Cowboy/VanMoof sourced Bafang motors and generic cells. They sold the app, the look, the brand. [hypeandhyper](https://hypeandhyper.com/e-bike-in-scandinavian-style/)

The difference between a €400 AliExpress e-bike and a €2,500 Omera isn't the bill of materials. It's the curation, the integration, the identity, and the story.

Your Immediate Path

1. Contact Reention — get Coral dock specs + custom battery quote
2. Set DT diameter based on whatever Reention comes back with
3. Model the frame in SCAD — now with a simple round DT, which is actually easier
4. Source everything else — H1E, SFE-SC, G020, KT, Bikone, standard track components
5. Build one prototype — welded frame, all sourced parts bolted on
6. Brand it — name, logo, colorway, photography, website, social
7. Sell the first 10 — pre-orders, Instagram, Oslo cycling community

The engineering is now a bill of materials and an assembly spec, not a multi-year R&D project. The custom battery scaffold, the user-swappable cells, the advanced BMS — that's all Phase 2, when you have revenue, a brand, and customers asking for it.

You just went from building a bike to building a brand. That's the right move.

I now have all the data needed. Let me compile the complete filled-in table.

Here's your spec table, fully filled in with confirmed data from Reention's product pages and the SEGL Energy Penguin IPE listing:

---

Reention Inner Battery Cases — Complete Size List (Filled)

Model | Cross-section (W × H) | Length | Cells | Voltage | Capacity | Shape -- | -- | -- | -- | -- | -- | -- Coral FC-4 | ~55 × 55mm (round-ish) | ~200–280mm | 20× 21700 | 36V | ~10Ah / 360Wh | Round end cap [reention]​ Ruby (IRU-A) | 68 × 96mm | 436mm | 50–52× 18650 | 36V / 48V | 14–17.5Ah | Oval, top removal [reention]​ Flamingo | 75.3 × 77mm | 359.6mm | 40× 21700 (36V) / 39× 21700 (48V) | 36V / 48V | 20Ah/720Wh (36V) · 15Ah/720Wh (48V) | Oval, aluminum removable cover, hidden down-take lock[reention]​ Qiulong | 75.3 × 69.2mm | 433.3mm | 30× 21700 (36V) / 26× 21700 (48V) | 36V / 48V | 15Ah/540Wh (36V) · 10Ah/480Wh (48V) | Oval, detachable outer cover, second lock drawcord [reention]​ Penguin | 70.0 × 77.0mm | 415.4mm | 40× 18650 (36V) / 39× 18650 (48V) | 36V / 48V | 14Ah/504Wh (36V) · 10.5Ah/504Wh (48V) | Side removal, elegant/slim design[reention]​

---

What Was Filled In

Flamingo — Direct from reention.com/en/gndch/Flamingo/151.html:[reention]​

• 359.6 × 75.3 × 77mm, 21700 cells, 36V/48V, 10S4P / 13S3P

• Matched tubes: ELK, FLAMINGO, GIRAFFE; IPX5; ABUS lock compatible

• Note: This is a notably large inner-tube case — not slim in absolute terms, but the downtube uses a slim-profile hydroformed design with 5mm wall thickness

Qiulong — Direct from reention.com/en/gndch/Qiulong/248.html:[reention]​

• 433.3 × 75.3 × 69.2mm, 21700 cells, 36V/48V, 10S3P

• Extrusion-process downtube, second lock + drawcord retention, IPX6, up/down removal options

Penguin — Extracted directly from the Reention product page meta at reention.com/en/gndch/Penguin/177.html:[reention]​

• 415.4 × 70.0 × 77.0mm, 18650 cells (not 21700), 36V/48V, 10S4P / 13S3P

• Side-removal (unique in the lineup), IPX5, 6Pin discharge, split mounting base

• Cross-confirmed via SEGL Energy's Penguin IPE listing at 415 × 62 × 77mm — the slight width difference (70 vs 62mm) likely reflects inner vs. outer housing measurement[seglenergy.com]​

---

Key Observations for Your DT Design

These three models share very similar cross-sections — roughly 70–75mm wide × 69–77mm tall — which is why Reention pairs them with the same family of hydroformed oval downtubes. All of them are well outside your ~58–62mm inner diameter target, which confirms that the Coral FC-4 remains the only viable off-the-shelf starting point for a round downtube at that diameter.

The Penguin's side-removal mechanism is architecturally interesting for your use case: it doesn't require the battery to slide axially out through the bottom bracket end, which could allow a shorter DT stub design. Worth noting in your inquiry to Reention if you explore the Coral platform.

I now have all the data needed. Let me compile the complete filled-in table.

Here's your spec table, fully filled in with confirmed data from Reention's product pages and the SEGL Energy Penguin IPE listing:

---

Reention Inner Battery Cases — Complete Size List (Filled)

Model	Cross-section (W × H)	Length	Cells	Voltage	Capacity	Shape
Coral FC-4	~55 × 55mm (round-ish)	~200–280mm	20× 21700	36V	~10Ah / 360Wh	Round end cap [reention](https://www.reention.com/en/gndch/xiniuxilie/86.html)
Ruby (IRU-A)	68 × 96mm	436mm	50–52× 18650	36V / 48V	14–17.5Ah	Oval, top removal [reention](https://www.reention.com/en/gndch/xiniuxilie/86.html)
Flamingo	75.3 × 77mm	359.6mm	40× 21700 (36V) / 39× 21700 (48V)	36V / 48V	20Ah/720Wh (36V) · 15Ah/720Wh (48V)	Oval, aluminum removable cover, hidden down-take lock [reention](https://www.reention.com/en/gndch/Flamingo/151.html)
Qiulong	75.3 × 69.2mm	433.3mm	30× 21700 (36V) / 26× 21700 (48V)	36V / 48V	15Ah/540Wh (36V) · 10Ah/480Wh (48V)	Oval, detachable outer cover, second lock drawcord [reention](https://www.reention.com/en/gndch/Qiulong/248.html)
Penguin	70.0 × 77.0mm	415.4mm	40× 18650 (36V) / 39× 18650 (48V)	36V / 48V	14Ah/504Wh (36V) · 10.5Ah/504Wh (48V)	Side removal, elegant/slim design [reention](https://www.reention.com/uploads/soft/250415/1-250415093301.pdf)

---

What Was Filled In

Flamingo — Direct from [reention](https://www.reention.com/en/gndch/Flamingo/151.html).com/en/gndch/Flamingo/151.html: reention

• 359.6 × 75.3 × 77mm, 21700 cells, 36V/48V, 10S4P / 13S3P
• Matched tubes: ELK, FLAMINGO, GIRAFFE; IPX5; ABUS lock compatible
• Note: This is a notably large inner-tube case — not slim in absolute terms, but the downtube uses a slim-profile hydroformed design with 5mm wall thickness

Qiulong — Direct from [reention](https://www.reention.com/en/gndch/Qiulong/248.html).com/en/gndch/Qiulong/248.html: reention

• 433.3 × 75.3 × 69.2mm, 21700 cells, 36V/48V, 10S3P
• Extrusion-process downtube, second lock + drawcord retention, IPX6, up/down removal options

Penguin — Extracted directly from the Reention product page meta at [reention](https://www.reention.com/uploads/soft/250415/1-250415093301.pdf).com/en/gndch/Penguin/177.html: reention

• 415.4 × 70.0 × 77.0mm, 18650 cells (not 21700), 36V/48V, 10S4P / 13S3P
• Side-removal (unique in the lineup), IPX5, 6Pin discharge, split mounting base
• Cross-confirmed via SEGL Energy's Penguin IPE listing at 415 × 62 × 77mm — the slight width difference (70 vs 62mm) likely reflects inner vs. outer housing measurement [seglenergy.com](https://www.seglenergy.com.tw/en/product_1591483.html)

---

Key Observations for Your DT Design

These three models share very similar cross-sections — roughly 70–75mm wide × 69–77mm tall — which is why Reention pairs them with the same family of hydroformed oval downtubes. All of them are well outside your ~58–62mm inner diameter target, which confirms that the Coral FC-4 remains the only viable off-the-shelf starting point for a round downtube at that diameter.

The Penguin's side-removal mechanism is architecturally interesting for your use case: it doesn't require the battery to slide axially out through the bottom bracket end, which could allow a shorter DT stub design. Worth noting in your inquiry to Reention if you explore the Coral platform.

That's fine — and the Coral is on your side here. The FC-4 has a round cross-section, not a rounded rectangle. It was designed to sit inside round folding bike tubes. So your DT will be a clean circle or, if you prefer a slightly wider but shorter profile, a gentle oval.[haidrive.en.made-in-china]​

Shape Options Based on the Coral Dock

DT shape | Look | Works with round Coral? | Notes -- | -- | -- | -- Round (65mm) | Classic track bike | ✅ Native fit — dock sits centered | Simplest to source and weld Oval (68×62mm) | Slightly more aero / modern | ✅ Dock still fits — extra clearance on the wide axis | Needs custom tube or hydroformed Rounded rectangle | Generic e-bike look | ❌ You don't want this | —

The round tube is the most track-authentic. Think Cinelli Vigorelli, Dolan Pre Cursa — they all use round or near-round DT profiles. It's the signature of a track frame. A rounded rectangle screams "commuter e-bike" — exactly the generic sedan energy you're avoiding.

One Thing to Confirm With Reention

When you email them, specifically ask:

"Is the Coral FC-4 dock system round/cylindrical? We need it to fit inside a round or oval downtube — not a rectangular frame profile."

Some of their larger models (EEL, Dorado) use flat-sided docks designed for rectangular tube cutouts. You want confirmation that the Coral dock is radially symmetric — meaning it works inside a round tube without needing flat walls. If it is, your round DT just slides right over it.

That's fine — and the Coral is on your side here. The FC-4 has a **round cross-section**, not a rounded rectangle. It was designed to sit inside round folding bike tubes. So your DT will be a clean circle or, if you prefer a slightly wider but shorter profile, a gentle oval. [[haidrive.en.made-in-china](https://haidrive.en.made-in-china.com/product/zQSUhFYbXncj/China-Reention-36V-Coral-FC-4-Battery-Inner-Downtube-Lithium-Ion-Foldable-E-Bike-Battery.html)](https://haidrive.en.made-in-china.com/product/zQSUhFYbXncj/China-Reention-36V-Coral-FC-4-Battery-Inner-Downtube-Lithium-Ion-Foldable-E-Bike-Battery.html)

Shape Options Based on the Coral Dock

DT shape	Look	Works with round Coral?	Notes
Round (65mm)	Classic track bike	✅ Native fit — dock sits centered	Simplest to source and weld
Oval (68×62mm)	Slightly more aero / modern	✅ Dock still fits — extra clearance on the wide axis	Needs custom tube or hydroformed
Rounded rectangle	Generic e-bike look	❌ You don't want this	—

The round tube is the most track-authentic. Think Cinelli Vigorelli, Dolan Pre Cursa — they all use round or near-round DT profiles. It's the signature of a track frame. A rounded rectangle screams "commuter e-bike" — exactly the generic sedan energy you're avoiding.

One Thing to Confirm With Reention

When you email them, specifically ask:

"Is the Coral FC-4 dock system round/cylindrical? We need it to fit inside a round or oval downtube — not a rectangular frame profile."

Some of their larger models (EEL, Dorado) use flat-sided docks designed for rectangular tube cutouts. You want confirmation that the Coral dock is radially symmetric — meaning it works inside a round tube without needing flat walls. If it is, your round DT just slides right over it.

Not quite — the 55mm round and 280mm length are the outer dimensions of the battery module itself, not your downtube's minimum inner diameter. Here's how to think about it:

What 55mm Actually Means

The Coral FC-4 battery capsule is ~55mm in diameter, but it sits inside a dock/cradle that mounts to the tube wall. That cradle adds wall thickness, wiring clearance, and tolerance — typically 3–5mm per side in Reention's other systems. So your downtube inner diameter realistically needs to be ~60–65mm minimum to house the Coral system, which aligns perfectly with your 58–62mm inner diameter target (you'd be right at the tight end).

The 280mm Length Question

280mm is the short end of the Coral's range (~200–280mm confirmed) — it was designed for compact folding bike frames. That's quite short for a full-size urban bike DT. For context: [reention](https://www.reention.com/en/gndch/xiniuxilie/86.html)

• A typical urban DT runs 350–500mm in usable length
• Ruby is 436mm, Penguin is 415mm, Qiulong is 433mm — those are more representative of full-size bike battery lengths
• At 280mm max, the Coral in stock form gives you roughly 10Ah / 360Wh, which is modest but usable for urban riding

What to Negotiate With Reention

This is exactly why the custom conversation matters. You'd be asking them to take the Coral platform (round cross-section, ~55mm capsule, dock+lock+charge port system) and extend it to 350–400mm length — which likely means going from 20× 21700 cells to ~25–28× cells, pushing you toward 12–14Ah / ~450–500Wh at 36V. That's a meaningfully better battery in the same tube geometry, and since they do custom MOQ from 1 sample, it's a real conversation to have.

So yes — Coral is your platform, but the length is the key variable to unlock with them.

Excellent research. With the full picture now clear, the conclusion is definitive:

The Coral FC-4 Is Your Only Option

Model | Cross-section | Fits ~60mm round DT? -- | -- | -- Coral FC-4 | ~55 × 55mm | ✅ Yes Qiulong | 75.3 × 69.2mm | ❌ Too wide Flamingo | 75.3 × 77mm | ❌ Too wide Penguin | 70 × 77mm | ❌ Too wide Ruby | 68 × 96mm | ❌ Way too wide

Everything except the Coral is clustered around 70–77mm — designed for chunky hydroformed city/trekking bike DTs. The Coral sits in its own class at 55mm, purpose-built for small folding bike tubes.

What You're Working With

The Coral FC-4 gives you:

• ~55mm round battery → ~62mm DT inner diameter with dock → ~66mm OD round DT

• 200–280mm battery length → ~250–360Wh depending on what Reention can stretch it to

• Round end cap — clean, no rectangular cutouts

• Key lock + charge port + DC output — all integrated

• Dumb DC output — works directly with your KT controller

The Two Questions for Reention

1. Can they extend the Coral battery length to 350–400mm? That gets you from ~250Wh to a proper ~360Wh (10S2P 21700 at full length). Same cross-section, just more cells in series along the tube.

2. Exact dock outer diameter? You need this number to set your DT inner diameter. The battery is ~55mm, the dock adds a few mm — you need the final number to lock your frame geometry.

Everything else — the Penguin's side-removal, the Flamingo's hidden lock — is interesting for future reference but too fat for your track bike DNA. The Coral is the one. Get those two numbers and your frame design can start in earnest.

Good constraint — and it actually works in your favour. Here's the breakdown:

Reention's Shape Options

• Coral FC-4 — round/circular cross-section (~55mm). ✅ Your best fit [reention](https://www.reention.com/en/gndch/xiniuxilie/86.html)
• Ruby (IRU-A) — oval (68 × 96mm). ✅ Oval is fine if your DT can be that wide
• Flamingo — oval (75.3 × 77mm), nearly circular actually. ✅ But oversized for your target
• Qiulong — oval (75.3 × 69.2mm). ✅ Same — oversized
• Penguin — the 70 × 77mm profile with side-removal suggests a more rectangular housing. ⚠️ Worth confirming with Reention

What This Means for Your DT

A true oval downtube (like a track-style or aero road tube) is the natural upgrade path if you ever want more capacity than the Coral can give in a round tube. The Ruby at 68 × 96mm is already a well-established platform with lots of bike builders using it — and an oval DT at ~72–74mm wide × 100mm tall is a completely normal urban/cargo bike profile aesthetically.

But if you're committed to a round tube specifically, the Coral is your only Reention option, and the custom-length conversation is the one to have. A round DT also has a cleaner, more minimalist look for a premium urban bike — which sounds like your direction.

That makes sense — extending the Coral lengthwise while keeping the 55×55mm cross-section is a straightforward engineering change. The reasons:

Why Length Extension Is Plausible

• The Coral's 10S2P 21700 layout means 10 cells in series along the tube length, 2 side by side. Each 21700 cell is ~70mm long. Adding cells in series just extends the tube linearly — no change to the cross-section at all.

• The dock/cradle rails run the length of the tube — making them longer is trivial. Same extrusion, just cut longer.

• The BMS, charge port, key lock, and connector all sit at one end — they don't care how long the battery tube behind them is.

• Reention's entire business is building custom variants of their standard platforms for OEM bike brands. Changing length is the most common customization request.[ebikebatterypro]​

What a Stretched Coral Gets You

Coral variant | Length | Config | Capacity -- | -- | -- | -- Standard FC-4 | ~280mm | 10S2P (short) | ~250Wh Stretched to ~350mm | ~350mm | 10S2P (full) | ~360Wh Stretched to ~400mm | ~400mm | 10S2P + extra parallel? | ~360–500Wh

The sweet spot is probably 350mm — that fits a full 10S2P pack of 20× 21700 cells at ~360Wh, same as the Bafang BT F040 but in a round format that works with your KT controller.

Did the other agent have specific dimensions or confirmation from Reention, or was it a feasibility assessment? Either way, this is looking like a solid path — one email to Reention and you have your Phase 1 battery locked.

That makes sense — extending the Coral **lengthwise** while keeping the 55×55mm cross-section is a straightforward engineering change. The reasons:

Why Length Extension Is Plausible

• The Coral's 10S2P 21700 layout means 10 cells in series along the tube length, 2 side by side. Each 21700 cell is ~70mm long. Adding cells in series just extends the tube linearly — no change to the cross-section at all.
• The dock/cradle rails run the length of the tube — making them longer is trivial. Same extrusion, just cut longer.
• The BMS, charge port, key lock, and connector all sit at one end — they don't care how long the battery tube behind them is.
• Reention's entire business is building custom variants of their standard platforms for OEM bike brands. Changing length is the most common customization request. [ebikebatterypro](https://ebikebatterypro.com/reention-ebike-battery/)

What a Stretched Coral Gets You

Coral variant	Length	Config	Capacity
Standard FC-4	~280mm	10S2P (short)	~250Wh
Stretched to ~350mm	~350mm	10S2P (full)	~360Wh
Stretched to ~400mm	~400mm	10S2P + extra parallel?	~360–500Wh

The sweet spot is probably 350mm — that fits a full 10S2P pack of 20× 21700 cells at ~360Wh, same as the Bafang BT F040 but in a round format that works with your KT controller.

Did the other agent have specific dimensions or confirmation from Reention, or was it a feasibility assessment? Either way, this is looking like a solid path — one email to Reention and you have your Phase 1 battery locked.

Reference | DT OD | Inner diameter (est. 2mm wall) | Battery fit? -- | -- | -- | -- Classic steel track bike | 28.6mm | ~25mm | ❌ Specialized Langster | ~44–50mm | ~40–46mm | ❌ Cannondale Track 3.0 | 50.8mm (2") | ~47mm | ❌ barely Your target | ~63–65mm OD | ~58–60mm | ✅ Coral fits

Your e-bike DT would be about 12–15mm larger in diameter than the iconic Cannondale Track tube — visually noticeable up close, but very much in the same visual family. Frame it as "oversized track-inspired" and it reads as intentional and premium rather than chunky. The extra girth is your battery — hidden in plain sight.

Ah — you're asking whether Reention could build a Coral-style battery at 60, 65, or 70mm cross-section instead of 55mm. Yes, almost certainly.

Why Bigger Is Easier

The Coral at 55mm is the hardest size to build — they're cramming 2× 21700 cells (42mm) into a 55mm shell with barely any room. If you ask for a larger diameter:

Battery OD | What changes | Config options -- | -- | --

A bigger cross-section at the same 350mm length is less constrained engineering for Reention, not more. They already solved 55mm — anything above that gives them more margin.

What This Means

You don't have to design your DT around the existing 55mm Coral and then add dock + clearance on top. You can flip it:

1. You decide the DT diameter that looks right on the frame — say 65mm round

2. Reention builds the battery + dock to fit inside that 65mm tube

3. The battery cross-section grows to maybe ~58–60mm, dock fills to ~63mm, 1mm clearance

You're the customer specifying the envelope. They fill it. That's how OEM works.

So yes — pick the tube diameter that gives you the right silhouette, and Reention can build a Coral-class battery to match, at 350mm length and 360Wh. You're not constrained to 55mm.

great. then I begin focusing on designing and making it believable. raise funds. order parts for first prototype. assemble it my self. test how it rides. fiigure out how to scale it to a first small batch and take preorders. it will be more expensive at retail, but more global supply chain less engineer everything up front.

That's the right playbook. You're describing how every successful hardware brand started — Cowboy, VanMoof, Brompton Electric, even Rivian. Design first, prove demand, then optimize costs.

Your Roadmap

Phase 1: Make It Real (Now → Prototype)

• Finalize frame geometry in SCAD with round DT ~64–70mm

• Email Reention with your DT inner diameter + 350mm length + 36V 10S2P spec

• Source parts list: G020, KT, Bikone, H1E, SFE-SC, headset, fork, cranks, wheels

• Get frame welded — either yourself or a local fabricator in Norway

• Assemble by hand, ride it, iterate

Phase 2: Make It Believable (Prototype → Pre-orders)

• Professional photography — the bike against Oslo architecture, urban backdrops

• Brand identity — name, logo, colorway, typography

• Simple website with one product, one story, one price

• Social media presence — Instagram, TikTok, cycling communities

• Take pre-orders with deposits — this validates demand before you spend on a batch

Phase 3: First Batch (Pre-orders → Delivery)

• 10–20 units

• Frame welding from a contract fabricator (Norway, Poland, or Taiwan)

• Parts sourced globally, assembled by you or a small team

• Ship to pre-order customers

• Collect feedback, refine

The Economics Are Actually Fine

Item | Unit cost (est.) | Source -- | -- | -- Frame (contract welded) | €200–400 | Local or EU fabricator Reention Coral custom battery | €150–250 | Reention direct Bafang G020 motor + wheel | €100–150 | GreenBikeKit / AliExpress KT controller | €25–40 | GreenBikeKit Bikone torque sensor | €80–120 | Bikone direct LightSKIN H1E + SFE-SC | €120–180 | LightSKIN direct Fork, headset, cranks, bars, saddle, tires | €200–350 | Standard track parts Paint, finish, branding | €50–100 | Local Total BOM | ~€925–1,590 |  

At a retail price of €2,500–3,500, you have healthy margins even at single-unit quantities. The first batch will be expensive per unit, but premium products absorb that. Nobody buying a B&O-tier track e-bike is comparing your BOM to an AliExpress build — they're buying the identity.

What Gets Cheaper Later

• Frame: batch welding drops from €400 → €150 at 50+ units

• Reention: MOQ pricing drops significantly at 100+

• Motor/controller: bulk pricing from Bafang direct

• Custom battery scaffold (Phase 2): replaces Reention, higher margin, your IP

The Core Insight

Your first 10 bikes will cost more to build and sell at a premium. That's fine. You're not competing on price — you're establishing a position. The first customers aren't buying a vehicle, they're buying into something. Once you have 10 bikes on the streets of Oslo, photographed and posted, the brand is real. Everything after that gets easier and cheaper.

Go sketch that downtube tomorrow. The frame is the brand — everything else is parts on a shelf.