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Thanks Mickey. This swap was just me trying to beat the system. I thought if I spent a bunch of time watching scanning equipment for the laggards that I could replace them all and have a reliable 30 mile car with AC. The car's owner is not without resources. It wasn't about the money. She...

Hi Kiev, I did as many of the checks I could do and it pointed to a loose connection or a bad ground fault detector module. I went ahead and pulled the pack this morning and found that I had forgotten to plug the HV cable connector back into the ground fault detector module: Put Humpty...

Can you spot the newer cells? These were initially matched well to the others before test drive but I was champing at the bit for a drive so...

Howdy, I just completed my first stock cell swap on a friend's US spec 2012 i-MiEV with 82K miles. Swapped in 18 cells after carefully matching voltages. Got codes P1A46 in BMU and P1A45 in EV-ECU upon first wake up. No other codes. Cleared codes with Autel scanner. Drove car 7 miles and it...

Sorry, I am using new-to-me used cells. Not mixing in brand new cells. I bought cells that I thought were a relative match for what was in there already. It is now seeming that the "new" ones might be significantly better than the 82K originals but I have only capacity checked the worst "old"...

I am in the middle of a stock cell swap on a friend's car and I would have made the same error in thinking that cell #88 was the last cell in the string and the most positive. Not sure what they were thinking. I am shooting for an installed cell voltage of 4.01. Hopefully this will be high...

I just spent the last hour testing different dongles on the three apps I have for the i-MiEV; Canion, OBDZero, and Car Scanner. I do not have Hobdrive loaded and really don't want to pay for it as I have three apps that work and also have current possession of a bidirectional Autel Maxicom...

I used Aptoide to sideload the Canion app and this dongle was the one that either went bad or there was some change to the app that rendered it nonfunctional.

I just bought a VLinker MC (no +) for around $40 USD and it works great with my ancient Android Nexus 7 tablet. Best connection I've ever had.

I would never recommend a used i-MiEV to anyone, ever. Too much chance of it having a degraded battery. They are mostly at EOL, end of life. There's a push to find foolproof battery cell replacements ordered directly from Alibaba vendors in China but it isn't quite there yet and what is there...

You can "side load" Canion from places other than Google play store. Sketchy? Why yes. I had to do that recently though when I couldn't get my 11 year old copy to work with the car I was working on. I deleted the app and was gonna reload from GPS but found it AWOL like you. As it turned out...

I found out that once you shave off all of the extra plastic around the seven weld points of the top web you can use M3x10 countersunk screws to reattach the top web to the cell holder. There is a cavity there and a countersunk recess just meant for those screws. Makes for a very secure hold on...

Better than pictures though is the parts themselves. Height differences are hard to discern from pictures alone. I received a full module and CMU boards (minus the cells) from an eBay seller in Canada. From this, I was able to figure out what was required to make spacer washers and bus bars for...

I just spoke with Piev and he's gonna provide me with some important dimensions from his new cells so I can make an accurate pair of jumper designs. But here is a quote below for two jumpers that are very close to correct. These are 3.2mm thick 6061 aluminum without tapped holes. SendCutSend...

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)...