"Custom" Cell layout for a case - help

BDamari

10 W
Joined
Aug 9, 2018
Messages
90
Hey guys, I got this big battery case, and I wanted like everyone to put 18650's in it. Unfortunately though, shipping genuine batteries to where I live is either too complicated or too expensive, so the only cell that is known in the community and ships to where I live for a reasonable price is the Lii-50a.

So, 26650 cells, in a case designed for 18650s. I understand that this is probably a mistake to begin with, but from years of using bulky metal boxes hooked to the frame with zipties, I really wanted a nice looking detachable case for a change. So I'm determined to make it work!

I already have the cells, 48 of them (16s3p), and when I put them in the case they fit... but that's also where the problem is.
The case, while having enough volume to contain the cells (and bms of course) is irregularly shaped, looks like an acute trapezoid, but with curves instead of angles or corners.
So Neither a zigzag or a grid layout works with this one. I tried cutting a couple of cardboard sheets in attempts to make a template of the inside, but I had no way of cutting it accurately. I even tried to cut a template of the 18650 holders but there are a few mm's here and there that are not occupied by the holders, so it's not relevant since I'm not using them.

Anyone have an idea of a way to do this?
 
A quick search around the forum for "pack design" or "cell layout" "battery case" should bring up plenty of ideas.

Perhaps this tool will help:
https://e4bike.ru/page/battery-shape-configurator

Also, check out this thread for optimal current sharing when planning a layout:
https://endless-sphere.com/forums/viewtopic.php?t=84412&start=25
 
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