60ah ADD ON build with Pictures

[expresso]

It's meaningless doing all these balancing things , when you are doing just 1P8S .
You'll take them all , good or bad anyway .

6awg (13.3mm sq ) wire for an add-on ?
You are making it unnecessarily difficult for yourself .

Ur right. Have no choice but to keep them. I just want to do the best I can. Can't wait to use it.

[Burgerman]

You dont want them unequal or almost discharged though. So you have to charge full, then remove some to know where you are.

[expresso]

would anyone have a link to this item where i can purchase here in the states and not have to wait a month to receive it ?

https://smile.amazon.com/dp/B019N0OMI8/ ... _lig_dp_it


searching and cant seem to find it here - everything from overseas and delivery is in Aug. - i though amazon was better when i went to check out and they told me the dates - i stopped - if not any other similar item i can purchase to wrap the pack safely

thanks

[Gnomatic]

Cut those sticky out push handles off. And use two rubber caps.

https://ae01.alicdn.com/kf/HTB1OWm1QFXX ... 40x640.jpg

I need them. I reach back and hook onto those with my arms when adjusting myself in my chair throughout the day. And my carers use them to move my chair away from my bed and over to where it charges when I'm not in it. My chair didn't come with handles like that. I installed them once I got it.

[rustyjames]

I need my push handles too. I drop stuff all day long and when I drop something (which happens everyday) I hook the push handle with my opposite wrist to pull myself back up.

[Burgerman]

Buy a grabber. Or small fit 20 year old blonde.

[expresso]

i figured out the screw size - it is 3/8 - i can fit a 10mm lock washer and a 3/8 inch flat washer worked fine - plus i found the rubber caps for them but of course didnt have enough of them -

question - normally i always see a flat washer and then the lock washer over it -

do i need to use a flat washer or can i just use a lock washer ?

if using them - - i forget the order it goes - - is this correct order ?

flat washer

ring termal - lug

lock washer

final nut to screw it down


is that correct ? with the headways - i didnt use washers at all - but with these its long enough and i can easily fit my charge cable lug and ADD ON cable lug and balance cable on one post and have room to tighten it down etc, -

i like to know what the correct order i should do it - if the above order is not correct

thanks -

[Burgerman]

I would add the ring terminal. Then a flat washer. Then the spring anti shake washer if I used it at all, then the nut.

Dont forget balance wire ring terminal...

No idea what a lug is. Here its slang for an ear!

Lugs...

[expresso]

i think lug is the ring terminals - i seen it called lug - copper lug etc,

so all the rings first - then flat washer and lock washer - i drop just a touch of locktite -

maybe wont work in that order if the flat washer is wider than the ring - in that case i have to put the washer first - then ring - lock washer and nut

but is it neccessary to use a flat washer or just the ring terminal and lock washer over it - i always seen it with both flat washer and lock when in use

just curious why i would need the flat washer in the mix at all ? my Cells look to have a flat base where the terminal will sit - as if it has a built in washer

i may be able to not use a flat washer at all - i was just curious as to why i always see them together - i never seen a item with just a lock washer or just a flat washer - always both - any reason for that or just what ever works ?

[Burgerman]

The flat washer goes over the terminal to spread the load. A spring or locking washer isnt really needed, in place you should use a nyloc nut.

Heres a nyloc nut and washer built in. All in one. Although expensive. You then would only need the nut alone to replace washer and spring washer and nut...

https://www.ebay.co.uk/itm/M4-M5-M6-M8- ... 2404128343

M10 is what you want!

[expresso]

yes those are the best - just like the ones used on the forks etc, - no need for washers or locktite etc, - but they will have to be screwed down alot -

the Cells came with the bolts to screw on - just reg. - kind - if i want to use them as they are - i need at least lockwashers to felt good which i purchased today for a few dollars - so i have them already - i didnt get the flat washers because wasnt sure of the size - so i got one flat washer 3/8 and it fits works -

its a bit larger than i need OD but ID 3/8 is fine - the lock washers i got today were 10MM and fit also - so really i can try just using what i have with out flat washers at all or get flat washers for a few dollars - or like you said - get the nylon ones and forget everything else

if i get M10 they would screw on for sure ?

while i am at it - i get a few of these

http://punchedibles.com/products/

a friend had some today i tried just a bit - not too bad -

[snaker]

expresso, do not forget the cell's metal case is POSITIVE

This pic worries me. You should insulate the unwrapped metal part on the top too.
download/file.php?id=8568&mode=view

I used lock washers too. The order is ring - flat washer - lock washer - bolt cap (or nut). I think the ring must be first because it needs to touch the cell's terminal. In my case the lock washers are very important, they keep the rings tightly touch the cell's terminals.

[Burgerman]

Yes metric is super simple its why the world uses it.

You find that almost everything in the EU, China, and most of the world is metric. Because its just easy.

Everything I buy, or own, will use metric threads. You can identify them easily just by looking.

In small sizes, M2, M3, M4, M5, M6 mm threads are used. After M6 then the only ones commomly found are M8, M10, M12, M14, M16, and up. So without seeing myself I cant be 100% sure but 3/8ths is about 9.6mm so M10 in the only one close. So much so that a decade ago, I threw all my imperial spanners, allen keys, sockets etc into the bin.

[expresso]

the picture is how i got them - but they were wrapped in plastic film - which i use it after i finish the charge and leave it alone -

when i build it - i guess i would wrap it top also - ? not sure how i will end up doing it - do you have any good suggestions ideas ?

i will use rubber caps on top of each post -

the middle part where the relief value is i think its called - can that be covered or should that be exposed to work in the event - hopefully never

i am sitting near the cell during charge and discharge - at least i am here home if not near it -

[expresso]

Yes metric is super simple its why the world uses it.

You find that almost everything in the EU, China, and most of the world is metric. Because its just easy.

Everything I buy, or own, will use metric threads. You can identify them easily just by looking.

In small sizes, M2, M3, M4, M5, M6 mm threads are used. After M6 then the only ones commomly found are M8, M10, M12, M14, M16, and up. So without seeing myself I cant be 100% sure but 3/8ths is about 9.6mm so M10 in the only one close. So much so that a decade ago, I threw all my imperial spanners, allen keys, sockets etc into the bin.

i agree it would be easier - but its not the standard here - so today at hardware store - when i said metric - i got that Ohh - not sure - cant fine - dont have
then i said 7/16 - didnt work either - haha

its 3/8 - thats the size i need and ordering the terminals in that size along with rubber caps -

[expresso]

Green PET Tape High Temperature Heat Resistant For Soldering BGA PCB

cant seem to find this here unless i want to wait till August to get it delivered -

what can i use to wrap it instead of this that is just as good and i can order it here in the states and receive it in a few weeks at least is ok - but amazon tells me delivery will be in a months time - not looking to wait that long - even though by the time i get around to wrapping it may be a month -

in the event it am ready to wrap it earlier - i want to have it here ready - being that my Main lithium chair is out of service for time being - i feel very limited without lithium now -

and excited to see how this 60ah ADD ON will do - in terms or range - i managed about 25 miles with a 36ah ADD ON - this is almost double

maybe 35 miles ? that would be great if i can get that much out of it -

[snaker]

I used a rectangle piece of silicon and made holes then stuck it on the top.

when i build it - i guess i would wrap it top also - ? not sure how i will end up doing it - do you have any good suggestions ideas ?

[expresso]

ok i can give that a try - i have some silicone on order already - to use in between the cells - - i can use it also going along the 8 Cell posts ?

the relief value thats in the middle of my Cells - does that have to be exposed ? or can i tape over it also

[shirley_hkg]

Our stores have numerous . A roll of 4'' @33m high temperature 280℃ tape is $6.50 US.

[LROBBINS]

Espresso,

Try searching (e-bay too, and perhaps electronics suppliers) for Kapton tape - that's a brand name, but people may use for listings that instead of the generic PET name. Most of the e-bay listings will be from China or nearby, but there are some in the U.S. too.

[expresso]

Our stores have numerous . A roll of 4'' @33m high temperature 280℃ tape is $6.50 US.

Thanks - i just ordered it from Ebay - it shipped already - coming from HK - i got the larger roll wider and it was cheaper than amazon here - i figure whats the rush - i wont be ready by then anyway most likely and i should have it by end of this month July -


https://www.ebay.com/itm/200mm-x33m-100 ... %7Ciid%3A1


this would wrap the whole pack bottom and sides - then i have to cut and trim to fix the top etc, dont think mines will come out as pretty as Snakers pack did -

Can i cover the middle relief value on the Cells ? or do i need to leave it exposed ?

[expresso]

Espresso,

Try searching (e-bay too, and perhaps electronics suppliers) for Kapton tape - that's a brand name, but people may use for listings that instead of the generic PET name. Most of the e-bay listings will be from China or nearby, but there are some in the U.S. too.

thanks and your right - i just checked it on Ebay and they have it here - but i already ordered the large roll - coming from HK - its ok i need some time to do the wiring anyway - dont have the same help as i had when i built my full pack - no sure rushing

but i may buy some of that also - smaller size could be useful

https://www.ebay.com/itm/40mm-X-100Ft-G ... xyUylTQfxK

[expresso]

Does this Tape stick to itself or do i need to get Tape to hold it in place ?

https://smile.amazon.com/gp/product/B00 ... UTF8&psc=1


i got some of this on the way - hope it works to hold it in place

[Burgerman]

Its sticky one side. Hard to cut, needs sharp scissors. I use it on model planes to join foam wings. High tensile strength.

[expresso]

Charging is coming alone pretty fast - tomorrow i will be doing the last cell -

i wrapped up the bottom of the Cells also and top a bit - since they are exposed on the bottom - i feel better this way - till i start to wrap it better

looking over the connectors - the wiring will be very short runs - not sure i can bend it like a loop or try to make it straight from one cell to the next

i measured the wire will be around 3 inch long - will have to see if can add the ring ends on such short wire -

on the top of the Cell - theres the little pressure relief i believe is what its called -

When i wrap the whole thing with the PET green tape - Can i cover that pressure relief tab in the middle of the cell also or do i need to leave it exposed for it to do its job in the event its needed ?

[Burgerman]

You are connecting neg to pos, 7 times. So it will be easy. Like this: ///////

[expresso]

Oh i didnt think of lining them up that way - i will see how that work

i was thinking of lining them up the normal way and then having to make a loop -

your saying line them up all the same way and then connect them in a line sideways - good idea - that may work better with shorter wires then

and can use 8 awg in that case maybe - if not 10 awg should be fine i think

thanks - - one left to charge and then start to build - waiting for the rest of the items - PET tape end of month

[Burgerman]

Did a 12V one that way a year ago for a hobby helicopter flyer so he has a pack on the feild to run his chargers. 100Ah cells x 4S. It allows a little flex so the terminals dont get damaged, works well. Plastic Calb cells.

[expresso]

BM just in time you mentioned about the wiring connectors - i put them together - coming alone much faster nicer than i though - still ways to go - its the wiring i have to make - charge cable etc -which will take me time - but i was about to put them together the normal way - good thing i didnt - wiring will be short this way also but should be better to make - hopefully

i may just use 10 awg for the connectors - its short - maybe i see if how 8 awg looks or works - things changed if using 10 awg - i hope the ring lugs i got will still work - i got them one size larger to make it easier to solder them after crimping - but now if i use 10 awg - maybe they may be too big - or else i double the wire end and wrap solder around it -

i semi wrapped it for now - BTW - thats not my Pink Toe you see in the picture - haha - thats Quickie - she was helping me wrap them up and cut the silicone sheets to size

[expresso]

few more