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This is exactly the sort of experimentation we have come to love. Good job Will. (y)

I used an insulation material that is only 3mm thick. I then compressed the cells with threaded rod and end restraints, such that the nuts were tightened so that i could only just turn the threaded rods by hand. This leaves the pack as one unit, but allows for a very small amount of expansion...

I have just finished installing the permanent flexible cell busbars and flanged studs...torqued to 4nm...so now the proper testing begins. Discharging my 24v(280AH) pack down at 0.04CA the max cell difference remained below 8mv to 3.2v/cell. By 3.15v/cell it had widened to <20mv, 3.1v <62mv...

Forum is a victim of its own success. The type of video's Will posts, gives a little confidence to folks like me, that starts of not having a clue and begins to think that just maybe they can actually do this. Thus there are gazillions of questions to get answered in a myriad of ways. Certainly...

So, have just completed second parallel balance.....set it at 4v , gave me higher amps which initially lit the CC led, then shortly after, changed to the CV led. Watched it rise constantly on the meter and terminated immediately on hitting 3.65v Going to call this done now. Charge voltage when...

The polycarbonate i used was really quite sturdy, but you can get 'stronger' multiwall versions, but at thicker widths. I think once you had it all secured together, it would become fairly rigid mass. When i go to do it, i will be getting copper flat bar cut to specific equal lengths to fit...

What was your reasoning for discharging to 2.0v/cell? I know you must have had a good reason, but i always thought 2.5v/cell was the cut off point for these type cells? I may have missed some of your discussion on this previously....but i'd be interested to know.

Hi jeephammer....i dont think this comment is fair representation of what i was saying..."Call me a 'FUD' if you want to "....i wasnt calling anyone FUD, i was calling the process of rechecking cell balancing every year FUD. I dont go out to my car and check the battery in it. From the...

@Chargery Thanks for that info Jason. You are the first person i have read, saying that you must do a 100% charge or a 0% discharge to maintain capacity. I have EVE 280ah commodity cells, which are not 'matched' from manufacturer, but have been top balanced by myself. If i push the cells into...

I used 3mm insulation material between each face. 8cells @72mm plus 9 layers insulation should = 576 + 27=603mm I tightened the end clamps till the total length = 594mm, which means i have compressed the insulation layers by 1mm each. The pack feels tight and rigid. the cells are not in much...

I thought i had read somewhere that without the shunt you no longer have over current protection...dont know if this is important to you or not?

i went from this to this.... If i was getting the studs made again, i would do it slightly different. I would opt to keep the stud size the same above the flange, ie 6mm instead of 10mm, as i realised later that you have more surface contact area with only a 6mm hole as opposed to the 10mm...

I can just picture everyone sitting glued to Will's videos with the outcome at the end, of either 'yippee' or 'oh f..k' .....lol.

Guys....this has been fantastic. I will be checking out everything that has been added, so thanks. Early hours of the morning here, so time for me to head off now. (y)(y)(y)

Thinking out load, in an RV setting, whilst we would do everything possible to restrain the cells in place, vibrations will still 'get through'. With this in mind, would it be better to make all cell connections with cabling instead of busbars? Which would be better....busbars would help provide...

I think you might be correct, but i'd guess at a logrithmic relationship....tails off very quickly, perhaps like this below...

I think the rule of thumb(for mobile) is dont go above 200AH cells and preferably only 100AH cells which are structurally stronger internally. I was wondering about a layer of 25mm kingspan insulation around each cell side, a temp controlled glass plate on the bottom and a fan to control above...

I adopted a different strategy for showering...so this is no help whatsoever to your project, simply a different way of thinking about issue. I like to take long showers after a hike, but wish to keep power consumption and water use to an absolute minimum. I therefore use a recirculating pump in...

The pack compression is such, that the wood can move freely under the bottom of the cells.

I was doing a discharge test using a heater and a very large fan, when i accidentally shorted a cell with my screwdriver... .....well the SHTF.

Some of my setup modifications i have made are: Placed a layer of compressible insulation between the battery cell faces. Installed 6mm to 10mm aluminium flanged studs on cell terminals. (All connections torqued to 4Nm) Installed flexible braided busbars across cell terminals and from cell pack...

lol steve, "and if "lucky" by the middle of this summer I'll be done " Aye Right, till you get itchy palms and need to start tinkering with something ha ha Just wait till you've gone 2 months cold turkey, doin nothing but looking at it.....it'll be, "where's ma fluke"...lol.

Yippee...done the updates through win 10...no issues whatsoever ...thanks guys (y) Better still, i still retained all my settings including SOC %, WH & AH. :)

Not exactly on topic, but kinda related...i externally powered my BMS through it's LVD relay, connected to a SSR, so that if activated the power drain of the BMS is terminated at the same time. At a disconnect of 2.6v/cell, this should still leave plenty in the cells even with their own self...

Looking fairly similar results to mine...so if we only ran down to 3.15v/cell, we should never need bother about divergence. I'm kinda thinking, that if you top balance to 3.65v/cell, this levels them out at this topline and any 'balancing' at lower levels, either passive or active, is...

Cracking interview by two relaxed guys....puts a lot of issues into perspective. Comes across that battleborne build leeway into every aspect, so worth keeping that in mind if comparing to other manufacturers at lower price points....may be prudent to excercise bigger tolerances in those others...

You should get another pack, split it down and use it to replace to two duff cells(use the two cells which most closely match your current pack), then build a 12v back up pack with the remaining cells for something else. That way your 'main bank' is as closely balanced as you could get...