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2009 Zero X Upgrade/Rebuild w/ sia155-48, cl700, & 28s12p p42as

The battery is basically finished now! Just some minor things left to do, namely extend the negative discharge lead so it actually reaches the bms, as well as design and print a shell to protect the bms and wiring from the outside world. Also I should note that I added a bit of foam between the final 2s thats jutting out and the aluminum endcap. I didnt feel great about it just rubbing on it without anything inbetween...

1778145580461.png
 
Maybe you could print a 2-part inside/outside gromit at that egress point of the case for the mains wires to mitigate the chance of repetitive abrasion and wear to the protective sheathing and insulation?

Though, it doesn't look like there is much room for those cables to shimmy shake. I'd kinda be more worried that the BMS tap wires have a very hearty sheath.

That all said, I'm still slow going on my first battery build. It's awesome to see others come together as inspiration... Hopefully this summer here too!
 
jkrienert said:
Maybe you could print a 2-part inside/outside gromit at that egress point of the case for the mains wires to mitigate the chance of repetitive abrasion and wear to the protective sheathing and insulation?

Though, it doesn't look like there is much room for those cables to shimmy shake. I'd kinda be more worried that the BMS tap wires have a very hearty sheath.
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Sorry for the late reply, Ive actually already done this! Forgot to take pics but I had some tpu laying around that I printed in a U shape and fitted in there. It would have probably been fine without since all the balance leads are wrapped in a few layers of tesa tape and the discharge leads both have nice shielding, but I would much rather that 'probably' not turn into a 'oh shit why is there smoke coming from my pack??' haha.
jkrienert said:
That all said, I'm still slow going on my first battery build. It's awesome to see others come together as inspiration... Hopefully this summer here too!
Click to expand...
Yeah haha, good luck with your build as well! Im really hoping to get this rideable soon since the weathers been pretty nice here recently and theres some fire roads and probably not private properties Id like to go explore!

Anyways, Ive also extended the negative discharge lead and printed the doghouse out of petg mostly as a test to see if itll fit. Tacked it in with hot glue. Ill eventually reprint it out of nylon and silicone it on there, though the current print might be one of those temporary solutions turned into a permanent one lol...
1778477555876.png
 
thebes said:
tesa tape
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Is that what's on the mains leaving the box too? I've seen that same wire wrap on tear downs of original Zero batteries, though I'm not familiar with the source. The lighter brown colored fabric tape in your last photo that goes lengthwise along the cable... Source for this?
 
I might have found a 2011 S with a bad battery. If I retrieve, I'll be cautiously embarking on a similar venture to get a new tractions system in place.

Any highlights level tips and recommendations to that effect?
 
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