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Just patching up the cover and will be ready for an install very soon.

It's still going to be a rush to get things ready for Saturday... The battery cover certainly won't be waterproof in time, but I might be able to get the internals finished.

I did hit the picks on a gravel road in the Ioniq and found it was really bad at pulling up. Felt like it locked up and pushed a pile of gravel in front of the tyres... But it should be better on bitumen surely?

I will need some of that stuff yes. It's used on bathroom tiles right? I will need to hack and modify bits of the cover to make everything fit regardless, so once that's done I'll get busy with the sealant.

The front busbars are going to be fairly easy to put together, but it does mean that the battery clamps will need to be as tight as practical, and as close to the modules as I can get them. There's barely a 1.6 mm gap there, so I'll have to ensure a sheet of FR4 sits in front of the busbars to preve...

brendon_m wrote: ↑Sun, 28 Feb 2021, 18:01 Looking good.
Hope to see it at electrikhana

Everything will need to go right, but we'll see how we get on.

All I need now is the sheet metal clamps. It's T I G H T... I think I'll be doing some fibreglassing on the enclosure to make it fit.

Last weekend I welded every last cell and glued the top and bottom covers on. Today was supposed to be the day I filled them with potting compound - EPL-9 which is a polyurethane elastomer with a hardness ideal for keeping batteries snug. My plan was to drill out the missing cell and use this as a f...

They did have the guys in North Perth set up, but sure if they followed through with it though.
I rode the NKD - did not like. The steering geometry is all horribly wrong. Talk it up as 'nimble' all you like, but it steered like a trolley. Power was fine for the job at least.

Hmm, no images showing up. Chinese made stuff is often undersized on the connectors. It would need to be a minimum of 16 mm2, preferable 20 mm2 for the power of the bike.

I only put the Prelude build in the technical section because it wasn't my machine... But it sort of belongs there anyway.

I don't know much about it myself to be honest, other than to say that three 7 kW on-board chargers and a Type-2 inlet would make more sense. If you have room for them of course.

SEI is both necessary to protect the anode, and unfortunate as it depletes the lithium inventory. Crud has to come from somewhere, and the mobile Li+ ions are a good source. So gains in the SEI means losses in mobile ion stock. Net result is lower useable capacity and higher internal resistance. If ...

Work out what the DCIR of the cells are first.
0.5 V / 200 A = 2.5 mOhms. Not bad.

So if you had a nominal 96 of them in series for a typical 355 V system, your total DCIR might be 0.24 ohms.
200 amps at a nominal 355 V is 71 kW, but I^2 x R losses mean you're generating 10 kW of heat!

Finally, about 5 weeks after starting, I have spot-welded the last tab to the busbars. Last thing to do now is solder the 6 or 7 recalcitrant tabs which can't be welded. You can see them where I've ground back the passivated nickel surface. Then do the cell top welding (about 2 hours there) before p...

These are the ones I was thinking of. Plus the one @4Springs put together here on the forum.

ZEVA - https://www.zeva.com.au/
EV-Power - https://www.ev-power.com.au/webstore/

There are cheaper BMS's around, they just have less fruit. If fruit is your thing Batrium has it by the ... bowl full.

Oooh cheap Korean home storage batteries coming to a garage near you!

You mean use the Leaf battery as is? If you can use the CAN protocol to operate the BMS, then I can't see why not. You'd need a high voltage DC hybrid inverter though. It's much easier to pull the battery apart, sort the laggards from the good cells, re-configure as a 14s pack and buy a 48 volt hybr...

Volta wrote: ↑Tue, 09 Feb 2021, 22:11 Thanks for all the info. gents. Series is the next step. As for the comment by Mr Jones are you alluding to the fact I may be over the hill?

Tongue firmly in cheek. I'm sure you have a strong right foot.

Depending on your battery voltage you might not have the top speed you want, but I'm sure you're past all that now eh Dave?

Ah yes true there is that approach for sure. I see a guy on Endless Sphere has bought a pulse arc welder for welding 0.4 mm thick copper to cells directly. Does a good job, and 0.4 mm thick copper is about equal in conductivity to 1 mm aluminium, with none of the intermediate resistance of a nickel ...

Thanks, I just finished module #2. We had the remains of a tropical low come south to visit Perth, so while the cooler weather is very welcome, the humidity isn't quite so popular. I'm watching the busbars of the remaining two modules start to get progressively more and more passivated. Some of them...

thermal epoxy going on.jpg A shot of the thermal epoxy before the FR4 goes on. I have had to contend with some passivated sections of busbar which will not take a spot weld. I can't even solder it. But as they might only impact half a dozen cells per busplate, I can't really justify making a new on...

It's bollocks. Two years overdue and full of nothing. Literally seeks to just do nothing and let the market sort it out. Actively promotes 20 year old technology (hybrids) as new technology and lies about their supposed advantages. Taylors comments today were littered with contradictions. "We see no...