The battery builders club

Finished this pack up past few days 10s5p of 40T. Old pack got water damaged and had a cell melt down (-.11v on that P group, no I don’t know how that happens).


Well that’s no good, anyway, have some battery beauty shots.


Double wrapped (first in blue, then in clear). 3rd wrap layer after it’s installed and soldered. Trying to make this battery a bit more waterproof than the last one, this customer likes riding on the beach and CONTINUALLY brings me his board after it’s gotten wet. The less I see of this board the better.


All wired up and manually balancing each cell.


Final shrink wrap and glue down. Charges perfectly, balanced, perfect. Very proud of how this one turned out with great welds and much improved soldering. First time working with battery PCB’s, and I gotta say it’s the way to go for flex packs. Sadly my next project is just a massive brick for a scooter so I’ll miss them.

Now somehow the ESC is having issues with motor control and detection, it’s flipsky, it might have been slightly damp. Oh well, customer wants the stormcore so I guess this board is gonna sit in my garage for the next month if anyone want’s to suggest things to mess with. Ping me on the esk8.news discord marsrover#1649. This is the battery thread, so I’ll stop talking about flipshit.

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would a nylon 3d print do the job?

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you should prob have fishpaper and foam, that should do the trick.

Sounds fine to me, plastic is plastic. Well other than PLA, I wouldn’t trust that. ABS is good, nylon is good. If you’ve got a printer, might as well. I’d still use fishpaper on both sides as well.

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yeah i got that

aight thanks guys

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Yep i use some failed PETG prints for exactly this. Works like a charm.

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Does kWeld’s USA distributor give tracking info?

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Yep, how did you order? I had USPS tracking info the day he shipped it

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Emailed him at 2 nights ago, he answered in the morning and sent a PayPal invoicethen said he’d be on it

I just used facebook messenger for all my order stuff, maybe he doesn’t check email as often

Yeah I got USPS tracking relatively quickly as well.

Btw there is a kweld thread too lol

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Hmm, t’would seem I have some reading to do

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One step closer!
Wooden blocks are shortened battery jigs. All nese tabs are now glued in!

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@Scepterr
Isn’t this a huge design flaw? All the current flows through these small traces


Or am I missing something here? (like copper braid connecting the tabs properly)

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Thin stuff over a very small lenght can still transfer a fuckton of current

And you could probably put a piece of copper on the other side

yeah but that section is wayyy thinner than the connection on the right side of the pack.
There is gonna be some losses with 60 to 80 amps continuous flowing through that…
It’ll probably be just fine but it’s not ideal

Current will flow wheres less resistance, if you put copper on there it will go through it and not through the slim pcb traces

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yeah i know but there isn’t any braid on the nickel or copper reinforcing the traces. To my understanding this will be an easy and fast way for tb to build their batteries. Reinforcing traces or putting braid on the nickel would cost more time and therefor wouldn’t be done (probably)

the simplest fix for this problem would just be bending the nickel tabs the other way over each other and then solder them togehter on the pcb

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