Diy Tesla Powerwall ep37 Cell Holder Mod

[@jamest.5001]

I have always said . if you don't know what you are doing. just act like you do. and go at it! making it up on the way! it has gotten me through a lot! even my first girl! and the second! good work.

[@AveRage_Joe]

+James stranger Lol Troof, I pretty much make it up as I go🤣🖒

[@djguta24]

nice battery pack, love it more air flow for the battery

[@AveRage_Joe]

Thanks Mate! They have been working great the last few years!!

[@mikedee8876]

I like those cell holders...going to use your idea for a mower 36v battery that was an SLA. I like the mower, and I like the idea of being able to change out a bad cell easily.....kudos

[@AveRage_Joe]

Thanks Man! PVC was from Lowes and is 3/4" sch80 part# 49731. Got it near the sprinkler stuff. Last time I was there it was around $4 for a 10ft section!

[@pneumaticfx9897]

There is something cool / art like about the way a pack looks with the colours of cells and copper busbars. Yours are looking pretty sweet mate

[@AveRage_Joe]

Yeah, I was kinda thinking the same way, You should see it with the fuses :)

[@chrisxx012]

I like the idea that you could switch out batteries from the battery holder

[@AveRage_Joe]

+Chris Mccarthy Thanks Man!

[@JamesPossible]

exactly why i'm switching to this setup...easy change out down the road.

[@mobilesigngeek1693]

I do like your design that allows for it to be a little air cooled but I also like your dad's designed in a way because I wouldn't mind trying to put put it in a box where we cool with radiator fluid. Musk uses liquid cooling while charging so we can charge at a higher capacity and a shorter amount of time.

[@AveRage_Joe]

Thanks! My dads design is cool but needs a way to balance. Musk uses higher drain cells vs our measly recycled laptop cells that are only capable of 1amp per cell lol.💥🤘

[@stevedutcher3875]

Looking forward to you soldiering those glass fuses on your pack!

[@AveRage_Joe]

+Steve Dutcher Next video coming up, maybe tonight :)

[@AveRage_Joe]

Just posted :)

[@rhoemberg1969]

I am all about this have you thought about using magnets to connect power and cut one end with a wire between 2 small neodymium magnets not soldered but placed into a round centered inside the 3/4 PVC and hotglue pooled to fill? This would allow you to fully make your buss bars with the magnets and fuses already attached.

[@AveRage_Joe]

Thanks Man! Magnets would be cool but I would be afraid they would somehow loose connection. I cant say for sure since Ive never tested it tho!

[@rhoemberg1969]

@@AveRage_Joe I want to test it to see if it creates resistance in the batterys gonna use your design but add those fit on one side the other will be magnets glued to the cell groups copper fit 14s and glued outside on the negative .

[@jimginnyohio]

Nice. That pack is looking very pretty! With the new camera and music, my head was bobbin'. :-) Keep up the good work!

[@AveRage_Joe]

Thanks man! I was hoping it wasnt excessive at the end lol

[@pneumaticfx9897]

Looks like a good plan I reckon

[@AveRage_Joe]

Yeah I think it will work quite nice

[@jdeadman]

Interesting way to support your cells. I have a 3d printer at work and have been printing smaller count holders for my batteries. there is a nice customizable openscad file on thingiverse

[@AveRage_Joe]

I would be in heaven If I had a 3D Printer. I want one, the possibilities are endless!!

[@jdeadman]

AveRage Joe yea I'm limited to what I can print and when as it's in production most of the time but it's still awesome to play with. way too expensive for me to buy my own though

[@jeffkay2011]

Use a modified screwdriver or awl or such to scrape down each well one line or two as needed. The ridges will give some resistance to the battery so they dont slip through.

[@AveRage_Joe]

Thats a great Idea!!! Ill have to give that a try for sure!!!😲🖒

[@rtalbott7]

Using hot glue for spot securing buss bars... what else is holding them in place.?... seems heat would release them.

[@AveRage_Joe]

Yeah they can move a little with hot glue. I tried zipties at first but those melted. Ive also tried putting a few fuses at each end to hold it in place and that seems to help.

[@bostjantrancar9605]

nice.....what about balancers and top charging voltage and charging current and conectors between and fuses what fuses would you use melt fuses or circuit breakers.... what Inverter???

[@AveRage_Joe]

Whoa there cowboy, one question at a time lol JK. Ill have to monitor the packs with a lil volt meter untill I can afford a BMS. Not sure which charge controller as of yet. Ill be doing 100p14s. As for the inverter Ill be trying/attepting to use an APC Server UPS unit. I got 6 of them for free so I figured Id give it a go. For the cell fuses Im using the fast axial glass fuses that pop at 2amps. Ill be using anderson connectors on the ends of the packs. Soldering fuses now :)

[@bostjantrancar9605]

Ok I mean big fuses one on the + and - lead cable... About glass fuses today I got first 150 pieces 4A.... Now I intend to fuse all my packs (28packs/115ah or 48v/230ah) with them... Since I have seen your video about cooper wire and all I was a little bit concerned... All in all glass fuses is the way to go 👍 My setup is already running only without solar panels charging in the night when is cheaper electricity and discharge true the day.....main purpos of this is to see behaviour of all packs...I cycle them every day and use about 150ah without bms... And they are quite in balance... Next thing is to get some panels...

[@AveRage_Joe]

Nice, Ill be there soon. How many in parallel are in your packs. Yeah I need to get more solar. How close were your cells in mah when you put them together.

[@bostjantrancar9605]

ok I use ZPB30A1 to test assembled pack but first I doo usual testing the single cell changing with 1A discharge with 0.5A "liitokala" then the same battery goes on the sky mc 3000 charger for a nother testing is very accurate to measure capacity then I sort them... assembled pack is measured for capacity with zpb30a1 and add or thake away cells and measure again so that I get the wanted capacity.... I have only one zpb30a1 so every pack is measured with the same zpb30a1 in the end discharged with 5A from 4.2v charged and left one week to rest......if is voltage still 4.17-4.2 itis ready to measure the capacity with zpb30a1 if not is getting on the - side disassembled and checked for cells with bad voltage 2nd time add fresh cells and repeat charging and rest time and so on....

[@bostjantrancar9605]

ok I use ZPB30A1 to test assembled pack but first I doo usual testing the single cell changing with 1A discharge with 0.5A "liitokala" then the same battery goes on the sky mc 3000 charger for a nother testing is very accurate to measure capacity then I sort them... assembled pack is measured for capacity with zpb30a1 and add or thake away cells and measure again so that I get the wanted capacity.... I have only one zpb30a1 so every pack is measured with the same zpb30a1 in the end discharged with 5A from 4.2v charged and left one week to rest......if is voltage still 4.17-4.2 itis ready to measure the capacity with zpb30a1 if not is getting on the - side disassembled and checked for cells with bad voltage 2nd time add fresh cells and repeat charging and rest time and so on....

[@lloydprunier4415]

Looking good ! You are getting creative with that new camera.

[@AveRage_Joe]

Thanks man! Just trying to make it look fancy-er than it is lol.

[@jonason321]

that's one way to do it. good ole hot glue. Nice work.

[@AveRage_Joe]

Thanks man, figured id mix it up a but and use hot glue instead of super glue like everything else lol

[@thesufi]

Regarding your loose holders, I understand the 18650 size spec allows for some flexibility on cell width between manufacturers. Have you thought of using soft 18mm silicon pipe instead, with a bit of stretch in it? Or would that not be rigid enough to hold the whole thing together as a unit?

[@AveRage_Joe]

Yeah I dont think that would be rigid enough. I mean it would work but you wouldnt want to move the pack much.

[@paulkennett]

Nice camera work there Joe

[@AveRage_Joe]

Thanks man, just trying out new angles and making it look purty :)

[@tim0877]

Is there a reason for using the gray pipe versus white pipe

[@AveRage_Joe]

This is sch80 pvc and white is sch40 so its thinner

[@danielhughes6896]

what stops the batteries falling out the bottom?

[@AveRage_Joe]

Once you solder the negative wire from cell to bus bar they dont move much. The wire I used on negative side is 24awg.

[@JasonSimpson1966]

2 comments. 1) use tape around the spacer cells to hold the top layer in place while hot gluing it. 2) when you have your cells pre-racked the way you did, just slide the assembled cell hodwe down over them. Might save a lot of time.

[@AveRage_Joe]

Ya on the 2nd and 3rd I did use tape and a couple popsicle sticks laying across the holes to keep it flush with the cells. Ill give the 2nd comment a try :)

[@crazycarl9484]

Is each pack 100 p and you make the serial connections from negative to positive on the bus bars with your anderson connectors.

[@AveRage_Joe]

Yeah each pack is 100p and then connect in series with anderson connectors!👍

[@crazycarl9484]

Thanks I watched a few of your videos great work

[@Dingbat217]

Nice video and the cell pack looks good too! Just one question, how strong is that cell-holder pack, would it survive a drop or a bit of rough handling down the line? I guess you would have to build one completely and see how well it stands up to a bit of abuse to really find out! Are you in earthquake territory by any chance, the last thing you'd want would be a pack shorting out because it got shook to bits by an earthquake...

[@AveRage_Joe]

Thanks, Not sure about a drop. Maybe Ill use some of the extras and all the 1000mah to find out lol. Im not in earthquake country or at least big ones should happen in Nebraska. Yeah that would be a bum deal to have them all short out from a good jar.

[@jamest.5001]

how many cells per pack? I'm thinking about just 20 or 40, it depends on where I put them. 7s for a 24v system. I'm looking for the solder you used. I'm thinking about using nickel strips on the neg side. and 20gauge or larger wire on the pos. with 8ga. solid for a buss. any objections? if not forever hold yor peace! thanks . I guess my 125 watt solder gun will work? thanks again!

[@AveRage_Joe]

Mine is 14s100p. Yeah 7s for a 24v and any P is great 😜 I used radio shack solder in this video and it was great but there store closed down so I went with this goo.gl/JDWEZb and its pretty much the same. I personally would use nickle strip unless its the bus bar because if a cell ever goes bad it would be a mf to change. I use 24/25g wire on my neg side and it wont pop unless there is some serious current going through it. If you want a wire type fuse I would go with something smaller more up in the 28-34g. 8g for the bus would be fine especially if your doing smaller packs probly up to 40p. You can always add more packs in parallel. Yeah 125watt iron would be great!!!👍

[@DiyintheGhetto]

Hey Joe you know what would be nice a Small Video on how you made your Bus bar Gig-gy with it. That way we can make ours the same way :)

[@jamesturner2126]

Your cell holders are fuckin A-M-A-Z-I-N-G!

[@AveRage_Joe]

Thanks Man!!!😆🖒

[@Resetdigital]

Good night, how much of this pvc pipe.

[@AveRage_Joe]

The pvc was $3 or $4 for each and I think I got 7 of them to do all 14 packs and had plenty left over.🖒

[@crackdownex]

AveRage Joe I was looking at sch40 3/4 pipe and my cells are very loose fitting in that pipe your fits way tighter than the pipe I was looking at don't know why

[@kennethrea79]

Looks like he is using electrical conduit pvc

[@batterydiy7297]

Good job !!

[@AveRage_Joe]

Thanks Man!

[@Bluebark64FIS]

How about this as an upgrade...if the bus bars are smaller dia. than the all thread, try having the all thread stick out both ends and start measuring. the idea is to drill the all thread where it pops out past the cell holder on each. then tread the bus bar through all the studs. Then measure out a sheet of thin plexi to the size of the cell holder and drill for the plastic studs. then after you solder/weld all the fuses up, you set the plexi down to cover the whole bus bar complex and secure it in place with plastic washer and nut...or just the nut if your so inclined. Now you have both sides protected...from an accidental knock into other packs or various metal objects...plus, if you drill a slight indent into the plexi right above the LEDs on your long board the plexi ends will glow if a light comes on.

[@AveRage_Joe]

That is an interesting idea. I plan on using plexiglass dividers with Leds in them so they can light up. Id like to used rgb Leds that show the state of charge!😆👍

[@Oneupthesleevecustoms]

great idea mate nice video :]

[@AveRage_Joe]

Thanks man!

[@terrytexas8257]

I had to modify my packs also to make them more ridged.

[@AveRage_Joe]

How did you do yours?

[@terrytexas8257]

As you know, the interior shrink wrap is the wrap the cells came in, and only the outside cells need to be wrapped. This creates a problem with how each cell sit in the holders, thus there is a lot of movement and the pack isn't very ridged. I drilled holes in strategic places of the holders so I could pass through 11" zip ties down the center of the pack where no fuses will be. Coupled with the zip ties I use for my buss bars to hold them in place, and some hot glue in strategic points, the pack while not a solid brick, is very "tight" and less "flexible" than without these measures. There still is a tendency for torquing of the pack if you pick it up via the buss bar ends that will cause some of the fuse wire connections to break. So now I'm having to repair that. Using the zip ties for the buss bars turns out to have a benefit while working on the pack. they act as support feet and keep the solder points from being in contact with the workbench. I'll show you the next time we chat.

[@AveRage_Joe]

Yeah Ill have to take a lookc at your packs. I have 300 fuses soldered, havent had any connections break.

[@Oneupthesleevecustoms]

outro was sick can i double like this video

[@AveRage_Joe]

I wish! :)

[@JamesPossible]

awesome, i constantly switching hands. i actually use a left handed mouse with a reverse click and i bowl strictly left handed. to funny. like the stand off idea.

[@AveRage_Joe]

Lol I try to do the same thing with the left as I do with the right. When I am working on stuff Its no problem but if I try to write something down it looks like a 3 year old wrote it lol. I dont get it, same with brushing my teeth. Ya it trips people up big time bowling Haaaa. Ya stand offs are a must (kinda), I built a pack without them and it was a little flimsy. I also set the stand offs in a few cells trying to hide them but I think the edges would be stronger if I had the stand offs further out😉👍

[@JamesPossible]

yes, i was thinking the same, placing a couple stand offs to closer to the edge.

[@BMIGLOBAL1]

Hey Joe, i copied your battery holder (4s25p) with 3/4" PVC pipe. Your batteries look WAY more snug?? Mine is extremely LOOSE. I'm not a newb, so yes, i'm using original 18650 cells, and everything else... why are mine so loosely fitted in the battery holders? Help please! thank you

[@AveRage_Joe]

Did you use regular pvc? I am using sch 80 pvc.

[@BMIGLOBAL1]

haha i didnt know there was a difference. Ouch i look dumb. Thanks A Joe!

[@AveRage_Joe]

Its all good, this is how we all learn! Were are you? If in the US, I got them at Lowes!!!

[@mmarte1622]

Joe they look like electrical pvc. As they are grey on color. BMI Global 1

[@james10739]

man you should have just set that new one on top of the populated one

[@AveRage_Joe]

I did end up doing that after I made the video LOL

[@OffGridAussiePrepper]

You rock dude..... anyone tell u that shia laboof looks like u or is impersonating u??? muahahahahaha

[@AveRage_Joe]

+OffGrid Aussie Prepper™ Thanks man! No one has said I look like him before but have been mistaken for Eminem before on quite a few occasions lol

[@OffGridAussiePrepper]

Well I did say he looked like you cos he has not got a good reputation after his BS with the political crap he is pulling as a democrat.... if i said u looked like him u may have taken it as an insult... lol and I dont want that. I loved the transformer movies thou, he did good acting the character... but in real life he is like a spoiled rich kid brat who is brainwashed by the democrats and has no clue the ramifications of what they r doing to the world and not just the USA. Anyway digressing from that topic, keep on with the utube channel, u seem to have a natural flare for being a tinkering guru and entertaining and I cant get over how flukey u r fixing shit so easy, its like the tech gods love u or something. What ever subject u cover I will practically watch... gotta love the comedic factor... what a pissa. :)

[@AveRage_Joe]

I didnt take it the wrong way :) I honestly didnt know the name and the wife told me lol. She also told me about his pubic "opinions" and how he thinks the world should know ect... I dont pay much attention to that kinda stuff. Ya I do like those movies as well. Im more interested in taking shit apart and or building/fixing crap from crap lol. Thanks for your comment by the way, Its really nice to hear that people like to watch my videos on the random tinkering I do :) Im gonna go out and state my opinions to the world now LOL JK Bahahahaaa

[@Resetdigital]

top

[@AveRage_Joe]

🤘

[@blakejohannes7102]

Hey man, I'll give you $50 if you can fix my smart tv. Screen went black, but I can see the "white noise" screen if I shine a light on it. I'm in Omaha. Hit me up if you're interested in fixing it!

[@AveRage_Joe]

+Blake Johannes Whats the model#

[@blakejohannes7102]

AveRage Joe UN46EH5300F Samsung

[@AveRage_Joe]

Ill look it up when I get off work :)

[@jimlovell8439]

CUSS TO MUCH

[@AveRage_Joe]

Yeah I toned that down quick! Shouldnt be much of that if any from this vid on!😆🤘