Actually, Joe, I wasn't hinting at a tamper-device like programming, just that going through all this work would yield nothing as the BMS would only allow the same amount of energy as the original LEV50 cells. It's possible, like one of my cell phones that I bought a very large battery for, that the car will re-calculate SoC each time it is power cycled. I would fully charge the battery in the phone, unplug it and watch the charge drop from 100% to about 60% charge, then plug it back and it would then truly fully charge. The phone adjusted SoC to match the voltage profile of the battery. The only problem with the phone was that the SoC calculation would run out before the phone corrected for the voltage, or it would sit at 8% for a very long time.
Koorz has actually done this a few times. I drove a few miles, parked at the store with 14 bars, and came back out to find 15 bars of charge that took 3 miles to drop back to 14 bars. The SoC could jump around based on pack voltage, so it is possible that after so much time of constant SoC corrections, the car will do a re-calibration and open up to the full capacity. Sorry, I wasn't running CaniOn so I don't have SoC values. And, no, I didn't do much regen in the last couple of miles
I noticed when the pack in Bear was failing, that it would charge at full speed until one cell hit 4.11 volts, then it would switch to constant voltage mode and hold the cells at 4.105 volts. With the new pack and lower resistance of the cells, Bear now charges faster in the top 10% of charge than before. It used to slow down around 94%, but now goes to around 98% before slowing down.
Maybe it's possible to force the car to open up to the full capacity if you run the LEV50 cells down to about 1 bar, do the cell swap (dis/charging the new cells to the same SoC as the discharged LEV50s), then charge the whole pack with the car. If my theory's correct. Even as the car gets near 100%, the voltage won't be there yet, so it may continue charging until the cells hit 4.105 volts, regardless of the SoC calculation.
After a quick read through of the Australian i-MiEV forum, many of their questions and unknowns are already answered here.