Crossy

I now identify as a microwave meal: - I look pretty good on the outside. I'm often disappointing. and I'm done in about 5 minutes.

OK, I get what you are talking about now. I'm not sure it makes much difference to performance, but the presence of a smaller lug on top of the main battery connection may reduce the effectiveness. Commercial packs vary, but many use laser-welded cell connections meaning they have to connect to the cell interconnect. Of the three packs I've built all have the BMS sense leads on the interconnect bars. The first I actually soldered the wires on (you need a BIG soldering iron) the other two are drilled and tapped M4 with crimped lugs on the sense wires.

On their way to get married, a young Catholic couple was involved in a fatal car accident. The couple found themselves sitting outside the Pearly Gates waiting for St. Peter to process them into Heaven. While waiting they began to wonder; could they possibly get married in Heaven? When St. Peter arrived, they asked him if they could get married in Heaven. St. Peter said, "I don't know. This is the first time anyone has asked. Let me go find out," and he left. The couple sat and waited for an answer... for a couple of months. While they waited, they discussed the pros and cons. If they were allowed to get married in Heaven, should they get married, what with the eternal aspect of it all? "What if it doesn't work? Are we stuck in Heaven together forever?" Yet another month passed before St. Peter finally returned, looking somewhat bedraggled. "Yes," he informed the couple, "You can get married in Heaven." "Great!" said the couple. "But we were just wondering; what if things don't work out? Could we also get a divorce in Heaven?" St. Peter, red-faced with anger, slammed his clipboard on the ground. "What's wrong?" asked the frightened couple. "OH, COME ON!" St. Peter shouted. "It took me 3 months to find a priest up here! Do you have ANY idea how long it'll take to find a lawyer?!

Correctly sized (for cable and battery stud) ring-crimp/lug on the BMS cable. Everything thoroughly cleaned (sanded). Decent electrical jointing compound on the mating faces if that's your thing, some don't like it. Washer ONLY on the top, never between the crimp and battery. EDIT Not exactly what you have, but you get the idea.

I'd forgotten just how wonderful this track is... Thanks for reminding me ????

Lithium batteries don't out-gas like lead-acid do so I wouldn't bother with forced ventilation other than maybe for keeping things (you) cool. EDIT If you have your genset in there you may want ventilation that runs with the generator.

I have a large and cheap hand crimper that I bought ages ago in India, does the job well enough. Plenty of baby hydraulic ones on Lazada. I would go for one that does the hexagonal crimps for no reason other than they look prettier (then you put heat-shrink on anyway). Mine is something like this https://www.lazada.co.th/products/wjhh-50mm-crimping-pliers-network-pliers-i3895728927-s14951682121.html

Battery side. Under-construction photo, the wiring has been tidied somewhat and the larger battery box is now enclosed.

Remember the old adage about spoiling the ship for a ha'porth of tar!

LiFePO4 are very low risk and don't suffer from thermal-runaway (unlike Li-ion), so most fires involving them are electrical in nature. Good practices should prevent most if not all of these. The electrolyte does boil off, but it's non-flammable you just get clouds of white "smoke" (you don't want to breathe it mind). Our packs are in a battery shed, steel and Shera-board construction, decidedly fire proof and away from the house. About 5k US plus DDP shipping will net you two of these https://www.alibaba.com/product-detail/14KW-48V-51-2V-280AH-Pre_1600894719244.html The same seller has cells if you want to DIY. Shenzhen Luyuan are a well-known and respected supplier, no rubbish!

Yeah, Barclays sussed me some years back. Nationwide are still good ???? And, if needed I have Lloyds offshore (IoM) accounts in Sterling, Euros and Yankee Dollars.

Crimps https://www.lazada.co.th/catalog/?q=SC35-6&location=Local Compound just on the mating faces, there shouldn't be any gaps ????

What size cable do you have and what size is the battery stud?? EDIT 35mm2 cable, 6mm hole, from Lazada.

You only need a smear of the joint stuff on the mating faces but it does set after a while, still easy to take apart. I really don't like having a stud that's way smaller than the hole, it's not good practice and can lead to over-heating. Why not obtain and fit ring crimps of the correct dimensions?? But, as with all these things, Up2U.

You really want the bolt/stud to fill the hole in the ring-crimp, hence making an adaptor with two holes. What you want to do is not ideal but would work, but do ensure the surfaces are scrupulously clean and oxide-free before assembly and use an electrical joint compound. What sort of battery currents are you expecting??

I mean this: - Which is what I'm assuming you want to fix. Maybe I'm not understanding.

Could you drill out the BMS connector so it fits over the shoulder (washer on top) for a larger contact area? OR Make something like this from an inter-cell strip?

Does the hole in the BMS connector fit over the "shoulder" on the battery terminal? Otherwise, I'd modify one of the inter-cell strips with exact size holes and fasteners.

Yup, 't was definitely a bit wet-n-windy 716986328.553239.mp4

Ah, that explains why the normal Friday afternoon exodus traffic was ... Exactly the same as usual