Thanks all for your reply.
Like I said before, it has been a humbling experience.
We have learned allot since then. (Friends and I)
Now we add a BMS to every built.
I will try to address all questions:
I dont have more photo detail of the original battery before construction. But here are some examples of following packs, also a few months old.
Top Balancing, charging to 3.55v (charger setting for Lifepo4). checked all cells at the same voltage just after finished balancing.
View attachment 97703
this pack is a 8S2P, Just to show
@Supervstech the connection on the tabs. simple, mechanical, tab to tab, used fender washer on the original, more contact area. Loctite red. the cardboard on the original was to protect from shorting the screws on the tabs. (this one used battery building adhesive foam, more distance betwen tabs)
View attachment 97705
Regarding BMS, I did not installed a BMS on this pack. Subsequent to the fire, we went back and installed BMS on all packs.
@sunshine_eggo , thanks for sharing your personal experience with No BMS. thank G_d you had no fire.
Since BMS now is a given, I wanted more feedback in the design and construction, any improvements and any possible risks.
Again, thanks all for your input.