PINNED - ADD ON PACK Step By Step 30ah Pack build / pictures

[shirley_hkg]

Couldn't we have better choices of boxes ?

[shirley_hkg]

---

[Burgerman]

Come with seal? To keep explosion in?

Or:

[expresso]

If you can find a box that suits your needs - and fits - anything can work - the box i found is the best i find around here - closest to the size i need - without trying 40 different stores -

the boxes you show there Shirley would work fine - finding those is another story - if you have a direct link to purchase those boxes - that should work fine -

14 inches long is Min. to fit just right - if 15 inches - i can made it fit in the Bag - 10 inches high is nice to cover the whole Cell and 7 or 8 inches wide for 3 Rows of 15ah cells

i have not been able to find this size online searching google - not sure what i am googling - plastic box ? or Mens plastic shoe box is actually the one i am using - i find many - too large - too short - too wide - -

[expresso]

XT30, XT60, XT90, and SB50 size comparison.



XT30's are tiny!

Huge difference in sizes there - this is the reason for going with the XT 90 - size compact - and ease of connection - but if you can fit the Anderson and it wont be connected and disconnected all the time - what ever works for you -

but i wouldnt go below the XT 90 and 10AWG -

[Gnomatic]

BM would you post a preset for the PL8 for an LiFePO4 24v 8S7P 105Ah pack? Basically a clone of expresso's.


Thank you!

[expresso]

Its Just about done - only left is one cable with anderson end - to go from the ADD ON to the chair - then i can pack it up in my home made plastic shoe box

[expresso]

few more

[expresso]

closer shot

right now its ready to be connected to the PL 8 - and discharge and charge etc, test it - etc, - i will wait till i make the last cable and then do it so i can charge both chairs same day - and then connect them

its not the prettiest - wont win any beatuy contests with my plastic shoe box - but it works and fits perfect in the bag - closed - you never will see it - just use it - get home - flip the bag open on top - you have your charge cable there - you shouldnt have to remove this - if all goes well - if you want to switch chairs - take the Bag its in off the chair and hang it on another chair - as long as you have a Cable made on the other chairs - you just connect them -

[Burgerman]

very very neat!

[expresso]

very very neat!

thanks - its just my plastic shoe box its going in haha - but its going to be a nice fit in there - i would just need to cushion one side alot to fill the gap -

[expresso]

time to eat and have a few shots of something

[Gnomatic]

Pizza looks good.

My pack is coming along, but I must say, you are much better at cable management than I am. Great work!

[Burgerman]

If I were delivering, frank would be added to the pizza and I would collect the tablets.

[expresso]

If I were delivering, frank would be added to the pizza and I would collect the tablets.

..
$17.99 in that bill - is that for ONE Pizza or the whole order on that bill which looks like a few pies ?

well you wont like the price of pizza here in NY thats for sure - unless you get the $1.00 Slice - which sometimes i get a pie from them also - change it up - the Pie i got with Two Cannoli's


https://www.google.com/search?q=cannoli ... q=cannoli+


$26 dollars - cost of everything is out of control here - but the pizza was great

[Burgerman]

For all I think. Frank comes free.

[expresso]

ALL Done - its on the chair - Charged - Discharging now and will recharge again both Chair and ADD ON - NOT Connected - when all done - connect it and that should be it - HOPEFULLY

Its not as Nice looking as i was expecting - the Grey bag is nice - i picked grey this time because black picks up all the dust and you can see it easy -
the bag is a bit bulkier looking on the 646 chair - as it looks on the P222 chair -

its the best i can do - at least Everyone has an idea how its done - i can used to the bag there - the pros - it will give me peace of mind that i can travel as far as i like almost - and not worry about the Main 105ah pack in the chair to get too low - will make it easier on all the Cells - can do easy 50 to 55 Miles and not worry about it - to know for sure - i have to try it one day -

Pros- Everthing -

Cons - its outside the chair

[expresso]

Discharging it -


135Ah Lithium -

[Burgerman]

55 miles is a safe figure. You should still have 6 or 7 left over at that.

But as you say, you don't go that far so the cells get an easy life.

If you were to get a used brushless chair, 8mph (like my new one). It goes 37 miles to a charge stock on lead with about 40 to 45Ah usable from the grp24s...
So with your 135Ah, you would get 135 div by 45 = 3.0. So you would get 3 x 37 miles. Or 111 miles or better... With just a 90Ah lithium, you get 2x the 45Ah so thats still 74+ miles!

Where will it all end Charge every January for some users!

[expresso]

that would be amazing to get 100 miles -- i have to try very hard to do 50 miles - the best i did was 44 miles - and i had the other 36ah ADD ON with me that day to be safe -

the most i did with the 105ah pack was 40 miles - to be safe - and i really think that the Bad Cell i had there was bad from the start - more or less
i dont think 40 miles did it - but who knows -

well see how this works out - i consider it insurance for my 105ah pack - if thats all it does for me - i be very happy this week Thursday - first 90 degree day here - so i be using it first time thursday

Tires coming in next week - thats another little project - - we see how that works out -

[rustyjames]

Well done, expresso. I can't imagine going 44 miles in my chair

[SteveO]

For what it's worth, I think you've done a brilliant job. You should be proud of what you've achieved. Well done.
SteveO

[Burgerman]

Well done, espresso. I can't imagine going 44 miles in my chair

I have tried. You gotta get going early!

The real value is not going 44 miles. Its being able to get a call at 8pm to meet someone in a pub at the wrong end of town and never needing to worry if you can get there or back late in the day.

Range anxiety that limits what you normally "consider" subconsciously is gone. You may not even realize you are limiting what you do. Its a thing that builds over years and you become used to it. You may never actually run out of juice because you are making sure you don't without even knowing it!

But you do notice once its limits are gone! You suddenly realise you *can* go places late in the day without that battery meter anxiety.

[expresso]

yes its one less thing to worry about - and for me to do 44 miles - i had to get up very early - at least its early for me - i was out by 10am and didnt get back till about 5:30 pm - it was a ride and half thats for sure - was nice once i got over the bridge into NJ and rode the scenic route -

i will have to go back of course may not even bother with Cell monitor shouldnt need one - -

too bad i couldnt fit it all in the chair - but hey - cant complain

[expresso]

For what it's worth, I think you've done a brilliant job. You should be proud of what you've achieved. Well done.
SteveO

thanks - everyone can do this at least - and if you can figure out a better way to pack it - keep it slimmer overall - even better - the plastic box i put it in would fit 3 rows of cells which was my first intention - i used 2 row - good enough - if you work making the container slimmer to fit 2 rows of cells -
may be less bulky looking - but i have to say having a little extra room can be useful if you ever have to remove it - gives someone room to grab the pack and lift it up and out easier i would think -

always looking for improvements - so if anyone does it and makes an improvement - even better -

[expresso]

Well done, expresso. I can't imagine going 44 miles in my chair

thanks - Are you from NJ ? you also have a 646 ?

[ex-Gooserider]

Worth noting that the picture doesn't show the smaller Anderson PP15/30/45 connectors - they are about one 4th the size of the SB-50, I don't have one in hand for scale, but I'd think they are in the same size range as the XT-90... The current rating is what they can deal with for live make & break connections, they can handle much higher currents as long as they are already connected, essentially same as the wire's nominal rating.... I have seen them used for motor wiring on many chairs, and they are extremely common as actuator connectors in seating systems.

The three size numbers relate to the different contacts available, which accept different wire sizes... The shells are the same. They come in a bunch of different colors so you can do color coding easily, and the shells can be locked together to make any desired size of connector...

ex-Gooserider

XT30, XT60, XT90, and SB50 size comparison.



XT30's are tiny!

[Gnomatic]

Worth noting that the picture doesn't show the smaller Anderson PP15/30/45 connectors - they are about one 4th the size of the SB-50, I don't have one in hand for scale, but I'd think they are in the same size range as the XT-90... The current rating is what they can deal with for live make & break connections, they can handle much higher currents as long as they are already connected, essentially same as the wire's nominal rating.... I have seen them used for motor wiring on many chairs, and they are extremely common as actuator connectors in seating systems.

The three size numbers relate to the different contacts available, which accept different wire sizes... The shells are the same. They come in a bunch of different colors so you can do color coding easily, and the shells can be locked together to make any desired size of connector...

ex-Gooserider

Didn't have any of the smaller Andersons on hand when I snapped the pic. If I get some, I'll take another with those included as well.

[expresso]

i just purchases some of those PP15 power pole i believe they are called - for another little project after i am done here - and they are very small pins - they snap together a black and red connector - side to side - i didnt expect them so small - its the connector i need for a 12 Volt 15ah pack i will make next - the pack end will have a XT90 - then will need a cable in between to connect the two - which needs a PP15 on one end -

[rustyjames]

Well done, expresso. I can't imagine going 44 miles in my chair

thanks - Are you from NJ ? you also have a 646 ?

Yes, living a little south of Trenton. I have several 646's and 626's and lots of spare parts, so if you need anything let me know.