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  1. M

    Load testing battery packs - Carbon-pile load tester?

    Definitely a very pretty glow. Does it double as a nightlight? :-)
  2. M

    Load testing battery packs - Carbon-pile load tester?

    Anybody? Don't be shy.
  3. M

    Load testing battery packs - Carbon-pile load tester?

    Hi. After some exchange with others on this topic I built my own home-made load tester using bailing wire. (BTW, it worked fine and my 18650 cell modules performed wonderfully!). However, I was wondering if any of you have tried using a carbon pile load tester. They are not that expensive...
  4. M

    How to put a 60amp test load on 3.7v battery cluster

    Hey, thanks much for the explanation kdog, and thanks to all other for your comments. I think I get it now. Cost-effective test load achieved by controlled short and measured with watt meter. Sorry, but I gotta go now to buy a watt meter and make sure my fire extinguisher is fully charged. :-)
  5. M

    How to put a 60amp test load on 3.7v battery cluster

    Okay, maybe I don't need SUCH precise load measurements. But you get what I'm trying to do, right? Put a heavy test load on each module to test the contacts? I don't want to spend a gazillion dollars on equipment. But I'm also a little leery on the idea of load testing by using a wire to...
  6. M

    How to put a 60amp test load on 3.7v battery cluster

    I would like to know with a reasonable level of accuracy the exact load I am placing on the cells. So how do I know that the 60mOhm copper wire or the MIG welding wire is only placing a 60 (or 80) amp load on the module?
  7. M

    How to put a 60amp test load on 3.7v battery cluster

    Interesting idea (to a novice like me). But where do I get 60mOhm copper wire and how do I verify that I'm placing only a 60 (or 80) amp load on the cells? Fires tend to scare me.
  8. M

    How to put a 60amp test load on 3.7v battery cluster

    Thanks, but I need a test draw at around 4 volts, not 82 volts. Right now I seek to test each 3.7 volt module, not the completed pack in a series.
  9. M

    How to put a 60amp test load on 3.7v battery cluster

    Actually, a constant, accurate current is important to me in placing a test load on these 3.7 volt, 8-cell modules. 1. First, I want an accurate 60 amp load to mimic the maximum draw they will experience via my ebike controller (60 amps). I want to make the the copper compression contacts I am...
  10. M

    How to put a 60amp test load on 3.7v battery cluster

    Thanks. But I know just enough about electrical circuitry that the mention of an IGBT makes my teeth hurt.
  11. M

    How to put a 60amp test load on 3.7v battery cluster

    I would love some advice on testing equipment. I am a novice. I am building an 82V 18650 battery pack that is made from 22 individual 8-cell, no-weld, parallel clusters I am constructing. The 18650 cells are NCR18650GA cells each putting out 10 amps. The 22 clusters will then be hooked up in...
  12. M

    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    Hi. You list your bus bars as being .308 (inches wide) by .010 (inches thick?). Is it possible that you meant to list the thickness as .10 inches (or a bit more than 1/16 inch thick)? To me that kind of looks more like the thickness portrayed in your pics. Also, any suggestions on where I...
  13. M

    Need supplier for 380mm wide heat shrink wrap

    Thanks for the info. Yesterday, someone pointed me to some similar heat shrink tubing available on AliExpress, which I purchased. Unfortunately, the wrap I found, as well as that posted for sale on your Ebay links are very thin-walled, and probably will require at least three layers to provide...
  14. M

    Need supplier for 380mm wide heat shrink wrap

    Hi. I built a triangle-shaped glue-pack 18650 battery pack, but I'm having trouble finding a supplier of the size of PVC heat shrink wrap I need. Considering the dimensions of my pack I need PVC heat shrink wrap that is 370-400 mm wide laying flat. The desired thickness could be anywhere from...
  15. M

    Maintenance/Troubleshooting Chinese Spot Welder

    Thanks Syonyk. I appreciate the input regarding the copper welding tips. I didn't think they looked worn out. They just don't seem to have the same "zap" they had 100 welds ago. Perhaps I do have something wrong internally. I'll try to check it out. BTW I am using pure nickel tape, not...
  16. M

    Maintenance/Troubleshooting Chinese Spot Welder

    Okay. Let's make this easier. Who has a favorite battery tab spot welder they want to brag about or recommend -- whether it be a particular brand, model, or a simple DIY contraption (by "simple" I mean simple enough for a dummy like me to build)? What's simply the best battery tab spot...
  17. M

    Maintenance/Troubleshooting Chinese Spot Welder

    New to spot welding and need some help with welder maintenance/troubleshooting. Recently got a cheap Chinese "Sunko" combination spot welder and soldering station. I completed about 100 welds (with the hand-held unit) welding nickel tape to the negative terminals of various parallel clusters...
  18. M

    Spot welding Tesla cells

    Thanks for the info!
  19. M

    Soldering wire leads directly to nickel tape.

    Sound great. Will do. Thx.
  20. M

    Soldering wire leads directly to nickel tape.

    Looks good my friend. Thanks!
  21. M

    Spot welding Tesla cells

    Wow. Until I ran my finger over the positive terminals I didn't even notice that each cell has a tiny little left-over weld dimple. I'll use my dremel to polish these down. Thanks for the tip. Also, my welder has a hand-held welding pen, which I suspected I would have to use. I'll go slow...
  22. M

    Soldering wire leads directly to nickel tape.

    My question is about soldering copper wire leads directly to pure nickel welding tape. Basically, will these soldered connections hold well? I'm making a 18s/11p battery pack that will draw 60 amps maximum. I seek maximum conductivity and no hot spots in the pack. I am connecting the...
  23. M

    Spot welding Tesla cells

    No. There are no raised dimples. The positive terminals are flat, not raised. Thx.
  24. M

    Spot welding Tesla cells

    They do not, but I was planning on purchasing and using ring-shaped insulation tabs just to be safe. So, did your spot welding go okay? Did you experience any problems?
  25. M

    Spot welding Tesla cells

    Hi. Looking for some input from someone who has built a battery pack from Tesla cells, connecting them in parallel clusters via spot welding. The positive terminal of the Tesla cell looks kind of like a small triangle with the tips cut off. (See attached jpg.) I'm concerned it might be a bit...
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