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If anyone needs to make bus bars for their new battery cells I only need to know the cell's terminal to terminal distance and terminal diameter as well as what material thickness you want (though thickness doesn't really matter for quoting as you can specify different thicknesses and materials...

Hi Mike, I made that drawing to assist you with your super helpful guide if you chose to use it. It was unsolicited help and I don't mean to step on your toes. I think I made a logical error in my first attempt to recreate your drawing. I think I fixed it but I think the saw kerf between the...

I am leaning toward the design below in 3.2mm 6061 aluminum, 22mm wide. Hand tapped and inexpensive. Will need pair of A busses for ends of modules.

I have two 8S 67Ah Samsung SDI packs here that I use to power both my stereo amplifier and TV of all things and they started my enquiry into repowering the I-MiEV. Cells are sadly too large, I agree. The i3 bus bar at 30mm x 1.8mm equals 54 millimeters squared which is 50% more area than the...

Y'all will have to pardon me. I'm on a roll today. From: https://help.leonardo-energy.org/hc/en-us/articles/202899511-Electrical-resistivity-and-cross-sectional-area-of-conductor-cables-Copper-vs-aluminium "One of the major differences between copper and aluminium is that copper has a...

I think Kiev is right about aluminum. The terminal blocks are aluminum so why make the bus bars copper? If we can use the pem nuts for the 3mm thread then we can get the price for 77x pieces even in 2.0mm aluminum down to a more palatable level. SCS want's $1.23 each for the press fit (pem)...

I think these press fit nuts might be a better option since we could reduce the thickness of the bus bars to 1.6mm from 3.2mm. Cost for 66 pieces of Bus B goes from $436.26 USD for 3.2mm Cu down to $231.66 for 1.6mm. I think they could be installed with a vise or arbor press, worst case. Cell...

Hi Mike, I drew this if you wanna use it: The 54mm measurement in your drawing would not work in Cad based on your other numbers. If you see a mistake here please let me know and I'll correct it. Jim

Very cool. Thank you. May I ask what the CTC distance is on the cells you used? Based on what you have here your cell's terminals have different centers than Piev's. Jim

Welcome back to the Jiminy show. Here is a possible way to do all of the bus bars that eliminates the stock bus bars entirely. I have not modeled the daughter board to the CMU so this would require refinement when I do but you get the idea. Bus "C" requires your imagination as I have not added...

Belleville nuts as I know them are one piece flange nuts with a convex contact face which acts as a lock washer or, at minimum, a locking feature when torqued. McMaster-Carr used to sell them. I bought quite a few. It's a nice detail in this application.

Another bus option?

Ahh, flange nuts with integrated belleville washers. Neat! I used to use those for a product I sold in my former life. Thanks for the measurements! By CMB, do you mean the separate little temp sensor pcb attached to the CMU? I haven't quite caught on to all of the acronyms. Stock Mitsubishi...

The only thing I would beg to differ on is that all of the current of the battery will be passing through these bus bars. I would prefer they make as much contact on the cell terminal below and stock bus bar above. The outside diameter on the terminal's 8mm flange nuts are likely 17.5mm so the...

Based on the loose dimensions shown in post #245 the jumpers tie it all together nicely.

Hi Piev, OK, thank you. By getting accurate measurements for this cell I can create models and then assemblies and figure things out without having physical parts present. I will make the cell models available to anyone here. Can you confirm the numbers circled below in red with one of the...

Hi Michael, Nice write up! Thanks to you and your son for making this. Would it be possible to PM me measurements of the jumper tab below by marking it up in MS Paint so that I can have it quoted at Send Cut Send? I've made ballpark guesses below. I will change the numbers and repost when...

I found this article on prismatic cells doing research on replacement cells for the I-MiEV: Prismatic cells - Battery Design I found it interesting. Jim

Reconsidered my opinion. Jim

Other Yuasa cells: