60ah ADD ON build with Pictures

[expresso]

silicone sheet in between works fine -

[Burgerman]

Very pretty. Do we know what that weighs? Looks quite heavy for an addon. It should easily double+ the range of a pair of MKs on a stock chair.

Did you notice that this time, you asked hardly a question and just did it for yourself? Knowledge is great! And it gives you confidence and power over your life.

[expresso]

Very pretty. Do we know what that weighs? Looks quite heavy for an addon. It should easily double the range of a pair of MKs on a stock chair.

it does seem a few pounds more than the headways if you were doing a 45ah pack - it was shipped at 28 pounds - so its not too bad - i say its about 5 pounds at most over the current 30ah i am using - i am hoping to get about 30 miles - to be realistic -

the ADD ON is taking the hit the most - i noticed from recharging last time - i put back about 60ah - i was down to a few cells 3v - and change - so thats the limit which means the Lead used about 30ah also - even if theres more lead left - cant use it - which is fine - makes them last longer also -

[Burgerman]

This is what the diode we were talking about would do. Take more from the lead, less from the lithium to balance it up neatly. One diode should be all thats needed. In the cable to the chair.

[expresso]

yes i remember - soften the blow and even out the discharge between both packs - this way the lead will last alot longer since it wont never get discharged all the way - that works for me since i wont be getting new lead for this chair - and its a pain to change them out - removing the seating etc, - this way i know i am good for easy 5 years with lead in there - and the lithium also - if not a bit longer -

even if i was able to get that last 15ah of lead used - wont do much - a few miles at most - - i will respect the lithium limits - - for example - i used to have 36ah on this chair and i recall getting 25 miles more or less depending on the day - now i am using 30ah - 6ah less of lithium - but i noticed the difference in range - its a bit less now - again depending on the day etc,

this 60ah should give me ALOT more range - and still keep the lead in good shape for many years -

[snaker]

My wrapping is different. I wrapped each pair of cells by silicon sheet. Then wrapped the whole pack by PET and fibber glass tapes.

My cell size (WxDxH) is 13.5cmx3cmx20cm, so a pair has a size 13.5cmx6cmx20cm. I cut the large silicone sheet into smaller sheets 25cmx40cm. I used each small sheet to wrap a pair of cells. The result was that 5 sides (except the top) were fully wrapped by silicone. Especially the bottom side was thick because it had 4 layers of silicone.

It is something like making rice cakes. In this video they use 4 leaves/sheets instead of 1 as mine. you can see the bottom has more layers therefore thicker.


youtu.be/2fYcwR3-Yx8

[expresso]

i know your did a great job snaker with the wrapping - you must have alot of room to make it fit after all that wrapping -

i have no idea how i will finish it up - i am sure it be fine but not as neat as yours for sure

[shirley_hkg]

Your box is plastic and you are hanging it in the air , so the bottom seems impossible to short . Enough is enough .

[Burgerman]

What about lighning?

[Burgerman]

Snaker, you wrapped your battery in actual leaves???

[shirley_hkg]

Snaker, you wrapped your battery in actual leaves???

Gonna get some green silicon sheets and show you how , when I do my next add-on .

[foghornleghorn]

My brother took my wheelchair apart and measured the available battery space for me.

260mm width
358mm length
244mm height

This would have to include all wiring and any wrapping for protection.

Looking at the way people are wrapping the cells, to get two rows of 8 in there and actually make this worth doing I need cells that are only 30mm wide. I'm struggling searching for answers myself, has anyone seen any approx 90Ah cells that would fit?

I was really tempted by the EVE-LF90 cells shirley_hkg posted here viewtopic.php?f=2&t=7766&start=160#p119719 but they are too wide

[Gnomatic]

My brother took my wheelchair apart and measured the available battery space for me.

260mm width
358mm length
244mm height

This would have to include all wiring and any wrapping for protection.

Looking at the way people are wrapping the cells, to get two rows of 8 in there and actually make this worth doing I need cells that are only 30mm wide.

These might be a better option for you.

viewtopic.php?f=2&t=7766&start=80#p118296

[expresso]

This has been a bit of a pain to make a Connector with Wire so Short - coming along slowly

Wrapping these Cells are very important since they are almost bare Cells - I will keep in mind how Snaker did his - Wrapping Each Cell before building it next time around - i think is much better and safer -

would be great if someone makes a Wrapping Cells Section with a step by step Correct Safe way to do these kind of Cells -

mines are half assed as they say - but in the end - as long as it works and its safe hopefully

[Burgerman]

Those are seriouslyheavy guage! Half that would have worked. But it cant hurt.

[steves1977uk]

expresso likes them big, black and thick! Like this...

Steve

[expresso]

yes steve - - you got it right - i like them all but nice and thick - keeps me warm in the winter

[Burgerman]

Thats scary.

[expresso]

Those are seriouslyheavy guage! Half that would have worked. But it cant hurt.

Oh - i wasnt sure so i went with 10 awg wire - the heat shrink makes them look thicker than they are - but are very short - which made it harder to get right -

i have wasted a few that didnt reach - still learning the ropes here - i have one left to do - then will check them all to see if they all fit - i didnt think about it before - i used the same cells to check each one i made - - but now thinking it over - i should have checked each one of the cells with them to make sure they fit on any of them - even a half mm too short - it wont fit - i learned the hard way -

[expresso]

expresso likes them big, black and thick! Like this...

bg37.jpg

Steve

that girl is pretty hot -

[expresso]

Those are seriouslyheavy guage! Half that would have worked. But it cant hurt.

in the future - 12 awg wire would be fine then ? the same wire that the PL 8 used on there stock cables ?

i tried to find copper or some kind of metal that i could use - went to a few hardware stores - home depot - nothing - that could be used to make the connectors and if i did find something - they dont make cuts or make holes in them etc,

having connectors ready made would have been so much easier - but as long as this works - something else i have to learn to work with -

[expresso]

Thats scary.

Really ? thats the Norm around here - you dont like meat on the bones ??

[Burgerman]

Thats not meat.

I took 35 lb of fat off her, she still needs to loose another 30...

[Burgerman]

Says a 20 stone me...

[steves1977uk]

expresso likes them big, black and thick! Like this...

bg37.jpg

Steve

that girl is pretty hot -

See, I know what you like expresso! But keep up the good work! Your new add-on pack is coming along nicely.

Steve

[Burgerman]

https://www.rapidtables.com/calc/wire/awg-to-mm.html

Says its about correct for an addon. I would have used 6mm square. You used 5.3mm square. Close enough.

[expresso]

i am confused now - its not too thick then ? in the future - this is the size to use at Min. ?

connectors all done finally - i checked with Volt meter - 26.5V - hand tigthen them for now -

[Gnomatic]

Pack looks good!

[Burgerman]

Yes its fine for an addon, a little small for the main pack - use 10mmsq. You need balance wires x9 now.

Which one do you prefer? viewtopic.php?f=2&t=8023&start=80#p121533

Also what size are your cells?

[expresso]

Yes its fine for an addon, a little small for the main pack - use 10mmsq. You need balance wires x9 now.

Which one do you prefer? viewtopic.php?f=2&t=8023&start=80#p121533

Also what size are your cells?

both are fine but if i had to choose - i take the meaty one -

On my Main 105ah pack inside the 646 chair - i used 8 AWG cable for the Power leads goin to the Chair SB50 - 8 AWG is closet to your 10mmsq i think or 6 AWG maybe a bit thicker than 10mmsq - i am not good with either standard or metric -

if i had to do it over - i may use 6 AWG cable for the mains - but cant complain - so far so good - going on the Third Summer with the 105ah pack -

this ADD ON is 60ah - will be replacing the 36ah i had on the Chair with Lead - should be an improvement over 36ah -