Cyclone 24v 25ah Flightmax Lipo build - lots of pictures

[Ypedal]

This took me wayyyy to long to finish, but voila :

http://www.ypedal.com/Cyclone/cyclone4.htm

 

[dogman dan]

Takes a while to do first class work like that. A great example to others, as always.

My approach to a similar 15 AH pack for my 24v lawnmower was easier. Tape em together. Not exactly the recomemded way. Once in a while, I seperate em to balance. Love your balance wire rig! Tempting to take apart my chargers and swap the balance wire connectors to andersons at the source. Loath those JST's after just a few months with lipo.

 

[Ypedal]

Yeah, those darn JST's ..grrrr.. with a bead of hot-glue they are not tooo bad but still a pain.

Would you believe with all the care and attention i put into this pack... i fubared it big time.. check this out :

Damn i suck.....

Spot the error :

 

[NeilP]

Nope, give up what are we looking for?

Wires too close to chain? wrong side? can't get to andersons for balance...difficult to tell from the pic

 

[Ypedal]

ding ding ding.. we have a winner..

Damn anderson ballance port right in front of the chain.. grrr....

Easy fix tho.. going to flip the pack around and make an extension wire, but talk about a newb mistake to make lol.. :lol:

 

[NeilP]

At first I could not see why that would be an issue ... who needs a Balalance port while cycling.... but then, I think I remember reading something that you had written about having a human BMS monitoring system, with BM or similar on the bike. Do I get extra stars for that?

 

[Ypedal]

With 25ah capacity, cell level monitoring while riding is not really needed, the HK ballancer gizmo can be taken along in a backpack and plugged in for an occasional check, but the ballance port still needs to be accessed every charge event, so greasy hands and fingers are not welcome... as well as the chain flinging grit and gime at the andersons... also not cool.. For now, a flap of tape over the port will do but this needs to be fixed right.. asap.

 

[NeilP]

umm. yes, dirt in the andersons not good

 

[Ypedal]

Well, turns out the existing wires will reach with the pack flipped around !

I'm planning no a key switch with relay and LED " power-on" light.. but before that, comes the road test !!..

 

[spinningmagnets]

Fantastic tutorial on all the steps to build a pack! If I was forced to have only one tutorial to show friends who were new to LiPo, I would definitely have this one at the top of the list. Well done, sir!

As someone else said: a pic is worth a kilo-word.