I thought I would show my finished battery pack.
Out of twenty four laptop batteries I purchased off of e-bay; I ended up using twenty of them to create this pack. You can see my previous posts on reviving what were at one time new batteries that had basically suffocated on the shelf.
My original thought was that I was going to be able to build two separate packs; but in reviving the laptop batteries that had been slowly drained/suffocated by their internal battery management boards I was only able to get back less than 2/3rds of the original capacity, so I wound up making one big pack.
My charger is a Thunder T6 Multi charger that has four output zones that will charge 1S to 6S, however the available charging amperage drops above a 3S setting.
Given this I designed the pack to be easily split up into four zones to match the chargers capability of balance charging four zones at once. This was necessary as the charging zones out of the charger share a common ground.
As you can see there are three black banna plug shunts that are easily removed to slit the pack up into the four seperate zones. I used color coded banna jacks; green is ground for each zone, yellow is 1S/V1, blue is 2S/V2 and red if 3S/V3 for a 12.6 zone.
Here's the pack being charged after a ride:
For a battery case I used a $8.89 plastic tool box that I got at the local walmart.
Here it is; attached to the cargo carrier on the bike.
After riding for 20 miles I had to remove the battery pack from the toolbox to do some minor repairs. Added silicone separator sheets between the zones after a layer of batteries shifted and had a minor short.
I think using banna plugs and jacks inside of the toolbox gives me some operational flexblity as I can easily take out a zone to revert to 36v from 48v.
More pictures with captions are available at:
https://picasaweb.google.com/fredsReprap/EBike?authuser=0&feat=directlink