My friend wanted to soup up his stock ebike, and wanted to build 2x 20s4p batteries out of P26A with my Kweld & 0.30mm nickel. He had never built a battery before. He did most of the work while I drank beer and said helpful things like “hmmmmm are you sure about that?” and “Nice gluing Michael J Fox”
He was dead set on using a Hailong G80 downtube case, so we had to design around that
Added fish paper to isolate the p-groups (not yet glued together)
I was trying to figure out a good way to cut the nickel. I decided to do it the hard way and model up the battery and draw where the nickel plates should be. Then we made wooden templates on the laser cutter.
We used those templates to arrange and fit onto the 100mm x 1,000mm roll of pure nickel
Both sides of the pack. In hindsight I don’t like how #10 turned out. I should have laid out the pack differently to make sure the nickel was 2 cells thick, but that was on the back side and we didn’t look closely enough at it
My friend wanted to do all the welding. He had some trouble finding the exact spot (no surprise after talking to his wife) to weld with the large plates of nickel covering the cells, so I laser cut our scrap fish paper as a guide
We then added battery leads and an LLT BMS.
All in all it turned out better than I expected