i see what you're saying. there may be room after all with the smaller radius tire. cause there wasn't w/ the 26" tire..
as you can see from this pic, i've just worm clamped it on the bottom tube near the bb. there are quite a few wires coming out of it with some big connectors, so rather than force them around the shock on the seat post mount, here, i'll have plenty of room to wrap them into a custom sewn velcro snack bag which will make for easy access:
so yeah, here i was extending the motor wires which had burnt up.
i'd actually replaced the stator from my other hs3540 which had upgraded phase wires etc, but then realized it didn't make sense to cut off all the good connectors. so i left it as is, compatible w/ infineon controller, and here just extended the stock phase wires. i was feeling a bit shy to mention it, but with upcoming testing, it may as well be known that i'm using stock phase wires - which will help bottleneck power to the motor so it can't heat up tooo much.
i would not be surprised if i have to upgrade them before i even start riding cause the insulation on the blue wire is cracked.
i'll know soon enough if there's a short! but for now i can't be bothered -- also, i'll need to find a new way to flip the bike w/o damaging the display on the bars!
back to the ghetto crimped clip job, i did have wee short when a strand strayed over, but it vaporized and there will be no more shorts, cause the bolted tab:
now has the big foam padding between it:
another on the opposite side:
and it's been taped down from various angles:
(and i'm treating it gently, and it's only temp until new 4s packs come in stock...)
so onto the pack. i made some copper bands out of some pipe clamps, crimped them down as hard as i could w/ hand crimper, and gave them a final squeeze with a garden trimmer:
my 60W soldering iron works fine for bullets, but i needed a bit more heat to solder the crimp. do you like it better than wire nuts?
so i connected the packs in series, paralleling only the ends, as the pairs will be parallel at cell level:
then i was getting pretty excited about hooking up the bms, i plugged the first one in right, then took it off cause it was wound around some wires and plugged it back in and ZAP!!
i'd plugged the 2nd 4s set at the same time as the first.
thank god andrey sent me a spare!
at that point i wasn't thinking clearly, and decided i had to remove it from the pack and use another battery. now i realize i could have cut off the shorted jst and soldered on a new one from an extension... so i cut out the pack and installed a new one. minor set back.
then i carefully attached all the bms boards, shrink wrapped them, and soldered bullets for charging, along w/ an extension to mate w/ controller:
and here just flipping a couple boards to show you, before taping them down to the tops of the packs:
i wished i'd added extensions to each bms board, for cell monitors or balancing, so i might just do that on the far sides of each bms board.
this morning i started freaking out that the 4s packs will charge faster than the 8s packs in bulk charging!
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