built a new pack for the evolve carbon these days! did a much better job overall compared to my very first pack, many small details are better, much better cells with the Sanyo NCR18650GA (even though the panasonic hold up well tbh).
Ill just drop some pictures here, maybe it will motivate you to make your own pack.
new bench from my granddad, fixed up with hard wood and aluminum angle for much easier and more professional alignment of up to 10 cells parallel:
like on my 10S4P battery, I this time gave it more thoughts about currents and how much each component can carry - set up the nickel strips to carry copper wires again since the nickel only supports up to 15A current. got a cool flux pen now - much easier and faster to work with
solder dots between cells, so minimum heat ends up in the cells:
serial connections fixated with spot welding:
phew, all 10x 6P packs connected:
and off we go connecting parallel packs in series:
the outer areas show all copper reinforced serial connections again:
while the middle connections are done by 6 nickel strips (= current up to 90A):
after lots of fiiber reinforced taping and prepared the "cable channel". it will be created when I fold the battery like a butterfly and provides a smooth protected channel for balancer and minus pole main power cable.
look at the backside - looks pretty beautiful. every rectangular bent nickel strip has a balancer cable attached with soldering iron.
adding minus pole:
and off into cable channel:
nice rainbow exit of all cables:
shrinkwrap & balancer 11-pin port:
work time: about 1 day!