Starting again with the LFP battery build

This is my second attempt to rebuild the failed EV battery where... let's just say mistakes were made leading us to ... now! I replaced all the EVE cells with the originally used AND CHEAPER GFB cells
Adding insulation to stop the outside of the battery from getting damaged or touching the mounting systems, addressing issues that allowed the cells to move around, replacing the foam (don't start I know lol ) with 3mm rubber under the battery and 1.5mm between the cells & replaced the busbars with ones that don't look so DIY..
My Brother against my very vocal wishes, went out and bought 6 active balancers and has added them to all batteries. His reasoning was solid - being mobility impaired (car landed on his head 20 years ago) if something goes wrong with the wiring under the car for the Batrium BMS he will be able to Bluetooth into each battery balancer and know where the fault will lie..
Previous video in this series • Stupid accident destro...
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Thanks for tuning in as always!
Pete
#diypowerwalls #hbpowerwall #18650ed #diypowerwall

[@AdamDeLayDIY]

Thanks Pete! Much better than what you had before! All that bare metal around the cells in a heavy vibration environment was kinda scary! While frustrating to have to undo lots to fix, at least when you had the one backwards it didn't cause any issues. Looking forward to the next update!

[@HBPowerwall]

I'm doing some capacity testing on the old puffy cells (results will shock you as the youtube kids say!) also plan on a road trip logging data back to my place, and maybe wack a generator under the bonnet to make it into a hybrid hehe

[@AdamDeLayDIY]

@@HBPowerwall I’ll be interested to hear how the capacity tests turn out. Those were really bloated cells. Best test is a road trip!

[@HBPowerwall]

hint was north of 90% !!

[@AdamDeLayDIY]

@@HBPowerwall WOW! Never would have thought that! Watching the update now.

[@HBPowerwall]

enjoy

[@marcusbinner9656]

Nice job! 👍 There's always room for improvement...

[@HBPowerwall]

Yes, thanks

[@Sylvan_dB]

Much improved! I think this is going to work well. Maybe not perfect and I'm sure someone will complain! (that's the point of the 'net, innit?) And the black looks great. Maybe hot pink would have been better? By the way, I understand the frustration of working on that rubber sheet! Next time, lay a sheet of paper over the rubber for a non-sticky surface (use parchment paper or waxed paper from the kitchen, copy paper from the printer, even any newspaper or other non-glossy paper from the junk mail - glossy paper sticks more and slides less on rubber).

[@HBPowerwall]

Didn't think of that, would have made the spacing and layout so much easier! I hoped I got it right this time.

[@RobinRastle]

polythene sheet

[@johnnodge4327]

That's definitely an improvement. The fiberglass board insulation is spot on. I'd like to see more rubber between the cells for compression, but understand you're trying to get some air convection for cooling. The only I'd like to see in a vehicle based battery is laminated busbars, which also have expansion profiles pressed in. Ideally there should be no lateral loads on the terminals, which solid bars do create, hence the use of laminated expansion profiles busbars. However you can on use what you can source.

[@HBPowerwall]

I'm not sure those busbars are fit for purpose but they were available but weren't cheap at all.

[@repairman2be250]

You have come a long way since the 18650 era. Hat off.

[@HBPowerwall]

Thank-You

[@caserio323]

you did a grate job. this look more safe than before .love the color.

[@HBPowerwall]

Yes, thank you

[@MrZugzug73]

Hi Pete is looking a lot better 👍you are on the right track 🚅can not wait to see the van up and running

[@HBPowerwall]

Be good to get it up here and I could do some much content with it, but it's so far away its quite painful driving for 2 hours in my little mini :P

[@offgridwanabe]

Looking much better and the paint makes it perfect.

[@HBPowerwall]

I agree the paint helps... although I feel the prep work might be lacking

[@retrozmachine1189]

It's the latest innovation in batteries, an inactive active balancer.

[@HBPowerwall]

LOL

[@SsgtStretch]

It's just a Wi-Fi balancer

[@HBPowerwall]

@SsgtStretch works perfect too hehe 😜

[@thedrake9460]

Thats what the flux capacitor is for yeah?

[@HBPowerwall]

oddly enough, no... flux capacitor is strictly for time travel!

[@5885ronny]

Hi habe auch lifepo4 Akkus 45,6 KWh und Victron Anlage 👍🤗 gutes Video 👍😊

[@HBPowerwall]

sorry don't understand and translate let me down

[@rjung_ch]

Messy or not, if it works and does the trick and is safe to boot, then nothing is wrong. Cheers 👍💪✌

[@HBPowerwall]

I want form and function - but i like the way this turned out -

[@THEZEST1357]

It's looking a lot safer/better than last time. There are small things I'd change but overall a tidy system now.

[@HBPowerwall]

I should have done it this way first hehe but live and learn...

[@sveip]

There are some bus-bars that are stacked zinced copper that are flexible (with a little hump) that will allow your cells to expand and contract (which they probably will) to avoid the poles to get torn off.

[@HBPowerwall]

Battery is in car now, but a few have said that - so will be on the lookout, we also didn't change any of the other cells to new busbars so I think that'll be a 'told you so' moment for us down the road - Major goal at the moment is a bloody test drive hehe

[@sveip]

@@HBPowerwall I can very much relate to the desire to just get it done 😀This type of flex busbars are very to easily available from ali-sellers, and being on top of the cells, very easy to swap, so better safe than sorry, I would advocate.

[@HBPowerwall]

my brother now wants to switch back to the copper bars for the 'amps' as he calls it

[@SsgtStretch]

Excellent work glad you found your mistake before you tried plugging anything in. It is a better battery!

[@HBPowerwall]

I'm so glad I got to fix it right.. I hope to get back down in 7 days to put all the batteries back in and take it for a test drive

[@sproket168]

Hey mate. Love the channel. Quick question where are you buying you're cells.

[@HBPowerwall]

We got these from BigWei At Springwood

[@olafschermann1592]

I also get better every build. First thing i do is painting a big red plus sign on the positive to avoid one mistake.

[@HBPowerwall]

Crazy that black isn't negative lol

[@olafschermann1592]

+1 for fiberclass sheet insulating on all sides.

[@olafschermann1592]

I did also epoxy sheet between the cells. You get those pre-cut in the right size. (For a reason)

[@HBPowerwall]

I didn't tell my brother what to buy that's just what he got, so worked with what I had.

[@krazed0451]

Here for the comments about appropriate PPE when working with fibreglass sheet 😂

[@HBPowerwall]

I had shoes on and a cap - :P

[@thomasrogers8239]

Eh, silicosis is great, it sorts out the weak.

[@krazed0451]

@@thomasrogers8239 I'd be more concerned about the itchy wank/sex later that day ;-)

[@HBPowerwall]

and the silly - hopefully the hepa vacume cleaner was up to the job cleaning up.. it was considered I assured you, the other option was hacksaw (finer dust and more ) or ripsaw...

[@smartazz]

Beautiful build 10/10

[@HBPowerwall]

Thank-You

[@RobinRastle]

can that battery box hold water? Drain plug? Put some foam rubber strips between cells at least. BTW dont you have laterite clay dirt roads in OZ like we have in RSA. Like constantly driving over corrugated sheets. The vibrations is very destructive?. So those cells are just going to jiggle around and come to grief eventually.

[@olafschermann1592]

Best price - capacity ration you get with EVE 280Ah cells. Best BMS ist the JK-BMS and if you use more batteries the JK-Inverter-BMS.

[@HBPowerwall]

there isn't a cold day in hell i'll downgrade to a JK-BMS

[@olafschermann1592]

I also bought a cheap thermal camera to see connection issues before something burns. You get FLIR phones or FLIR plugons for smartphones for an affordable price

[@HBPowerwall]

I had a flir one for my phone but lost it somewhere, now have a handheld one I love

[@arebear4797]

Can we loose the batrium and adopt JK BMS.

[@HBPowerwall]

Really would not enjoy that level of downgrade.

[@WaynesWorld999]

How did you not have immediate fire with the 3 top right? 1st cell opposite to other 2, so pos-neg-pos-neg. Eternal series.

[@HBPowerwall]

Excellent question.. might have made a great thumbnail lol

[@Sidicas]

Just stay out of the north half of the United States in winter and that LFP build should be fine!

[@HBPowerwall]

Luckily I'm in Australia !

[@RabbitThePat]

at 10:03, the fourth cell from the upper right looks backwards to me.

[@HBPowerwall]

QR Code is on wrong - it was in a box on it's own so figure it's from a different batch of batteries ? Time will tell If it is an issue, but it is installed correctly.

[@mrgreenswelding2853]

Did you get the cells from big wei?

[@HBPowerwall]

The new lot yes.

[@mrgreenswelding2853]

@@HBPowerwall were they a good price?

[@HBPowerwall]

wasn't too bad BUT those busbars seem way too much - $4 for one busbar and two screws - about 200 bucks for just the busbars!

[@BajanAlan]

I paint positive side red!

[@HBPowerwall]

In hindsight that would have been a cracking good idea

[@RobinRastle]

OBTW if you look how the cybertruck is built - see vids munro he fills his battery packs with urethane foam

[@olafschermann1592]

7:27 you see one battery in wrong direction. I wish they mark one pole ultra red

[@HBPowerwall]

YES!

[@MrDingaling007]

I see the single cell that should be the other way around. Ive done it too.

[@HBPowerwall]

I was so annoyed - I didn't see until I had put the Batrium BMS on and noticed it didn't have comms - did you notice the one cell with the QR code on the wrong side too?

[@MrDingaling007]

I was doing a 70S 250V battery setup for my Prius EV conversion and yep finally saw the qr code orientation the wrong way around lol.

[@retrozmachine1189]

@@HBPowerwall I was scratching my head wondering how the cell was reverse polarity and there wasn't huge sparking when it was assembled and flames now shooting out. Sticker on the wrong side, in all the youtube videos I've watched about battery assembly I've not seen that before.

[@HBPowerwall]

one cell came in a separate box we are assuming unfortunately it's from another batch perhaps

[@MrDingaling007]

Ah! Ok Yep. Good think that was noticed.

[@one4stevo]

IT'S WRONG.... Wrong color. Just kidding nice job.

[@HBPowerwall]

I agree - scrap it and start over LOL

[@5nowChain5]

Its a DALY! They are crap.😂😂😂

[@HBPowerwall]

They just reached out to me and offered sponsorship - will be fun to see if you're right :P (I accepted pending terms )