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

Cell fitting

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

Mock-up, outside

Mock-up, in place

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

Battery fitting

Cells in place, not connected

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

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

Battery installation

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