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1.  Cell arrangement

25 pairs

From most positive to most negative:

 Batt Bank Cells Arrang Loca Placement
  1   0    10    5S2P   seat rear-center
  2   0     8    4S2P   seat right side
  3   0     9    4.5S2P seat front-center-right
  4   0     9    4.5S2P seat front-center-left
  5   0     7    3.5S2P seat left side-rear
  6   0     7    3.5S2P seat left side-front
 __   _    __    ______ 
  6   1    50    25S2P  SEAT TOTAL

2.  Cell fitting

We made mock-ups of the cells using foam panels (construction material used for insulation).

Mock-up, outside

Mock-up, in place

3.  Battery construction

Seat batteries on the bench. Enlarge

Battery 1 Enlarge

Battery 2 Enlarge

Battery 3 Enlarge

Battery 4 Enlarge

Battery 5 Enlarge

Battery 6 Enlarge

4.  Battery fitting

Cells in place, not connected

Battery numbering (The picture is wrong: they are all Bank A)

5.  Cable prep

Prepare the 2 red cables in the under-seat area:

  • Remove the 12 V battery terminals
  • Do not reduce their length: the extra length can be shoved in as a service loop
  • Install 1/4" ring terminals
  • Put heat shrink tubing

Power cables prepped; note routing of front cable with respect to hose

Prepare 5 jumpers:

  • Cut 5 pieces of 4 AWG wire
    • 4 each 3" long
    • 1 each 10" long
  • Strip ends 1/2"
  • Crimp 1/4", 4 AWG ring terminals on each end
  • Put 1/2" dia, 1-1/4" long, heat shrink on both ends

Jumpers

6.  Battery installation

6.1 Install Batteries 5 and 6:

  • Connect the front red cable (the one that goes to the Big Red Button) to the most negative terminal of Bank 2
  • Shove the 2 batteries in place (it barely fits)
  • Keep the rear red cable flat against the back wall, so that it doesn't get in the way of the rear battery

Bank 2 connected, shoved in

6.2 Install Batteries 2 and 1:

  • Install battery B2
  • Drop in battery B1
  • Tuck the extra length of the rear red cable into the space behind Bank 2
  • Connect the rear red cable to the most positive terminal of Bank 2 (battery B2)

Bank 0 dropped in (battery B2 has to go in first), battery 1 connected

6.3 Install Batteries 3 and 4

  • Drop batteries B3 and B4 in place

Bank 1 dropped in

6.4 Connect

Install jumpers:

  • Cut 3" of 4 AWG wire, strip 1/2"
  • Crimp 2 ring terminals
  • Add heat shrink tubing

Right side jumpers installed; Center jumpers installed; Left jumper installed

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Page last modified on April 13, 2012, at 04:28 PM