OH ITS ABOUT TO GET REAL
BUILD TIME BB
so I got some wonderful ZBMSs, and we got a good idea of where to put the escs
Battery!
so gluing this was interesting. it ain’t no brick, and it aintm no normal stagger for this construction, so What i did was make 21 groups of 3 cells in a chevron config. shoutout to @YUTW123 for making good escs cases, they’re perfect for a battery lineup tool
and of course I need the most space i can squeeze out of my stuff so flexible and thin material is needed for isolation. so wht we do? Tesa tape! helllllll yeah. thicc enough to space cells apart, abrasion resistant (rated), and way more flexible than fiber tape. I’ve done this on quite a few of my old packs, and it’s done quite well so far, and it’s even made it into @Shadowfax 's new board!
wam a bam, ez pz and it’s pretty too. up next, tabs! I don’t got no fancy laser cutter and 8/10mm strips is janks so what we do? template, trace, cut, flatten! it took some time cutting, and some hand strength, but with good scissors, it came out quite nice.
we then got some welding! this was sketch AF, super scary, cause the chevron makes a very percarious situation where the middle cell sticks into the next group so one wrong move and we get skme zappies
but we good! After the main tabs were done, i got some 24x10mm strips of .2, and welded to the negative cell in each tab group, and bam we got some balance tabs! keeps the wiring way easier without needing them to bend around the edge (you’ll see how it goes). the hardes t part was welding a buncch between the 2 bars of packs. gotta be super careful, and put enough down not to add too much resistance. so we laaaaaid it down! (next time i might just do braided copper, that’s more guaranteed to be easier maybe? but it still works out with welding)
and final assembly! we isolate with good fiber, and some double sided tissue tape, super good to get them stacks together. bent th balance tabs all nice n flush, it’s looking hotter than my internet wife (wait, she dun exist nvm)
aight we keepin it on topic, but I didn’t get wiring done for a few days, but let’s keep it simple. wiring time!
so we got 2 rows, just straight down then back, esy peasy wiring job. gotta do all the wire swaps before it goes on the pack, no need to cross over and it’s just mm shefs kiss. tissue tape is perfect for laying the wires, no need to glu or anything of that sort just lay it and it sticks, and it’s thin! long as i got the order right, it’s a super fast process just trim strip and solder!
bam! battery pack wrapped and complete.