oatnet said:
Nice clean job, but OMG those bare, proximate terminals
on the top row give me chills. You may find that vibration makes the screws burrow through the cardboard on the lower row. When I tried this approach last winter, I used shorter bolts to reduce the chance of shorts, and nylock nuts. It was a lot of work though, so I'd be more inclined to buy the same kit ambrose did, or spot-weld the tabs.
I posted earlier about my conversation with A123 management about openning a factory window in Michigan. No go on that, but one of the comments about ebikers building batteries (yea, I know..) was that we'd never get it right, that it took the great expertise of the A123 engineers to get a battery right. At the top of their list was VIBRATIONS undoing a pack or wrecking havoc on the cells. I believe them - they did do extensive testing and do in fact know what will kill a battery pack. So don't disregard that news.
One more thing, a definitive NO to welding from me - again I've posted elsewhere. You want a construct that is reversible, so as to reconstruct a pack, removing & replacing just the cells that have died. See Agniusm's kit for the way to go - just buy the kit or see how to engineer a pack that solves both those issues.