I finally got all the parts and I have completed one of the two packs I am planning to build for my camper project. After a lot of research, lots of reading and a lot of searching for the right parts for my build, I finally got one done. My best friend was able to source me some very good condition ThunderSky 100Ah 3.2v cells. Most of the other parts were sourced from Amazon, local hardware store or stuff I had already. All told, I have less than $200 in each 100Ah bank.
I set out to build a full 12v pack that was functional, looked clean and serviceable. I did not want the end results to look hacked together. After measuring the size of the cells, I worked to find a suitable housing for them and the BMS. For the BMS, I ordered from @OverkillSolar a pair of 120A BMS's with BT and these are the new models with the shut off switch for the discharge side (charge side still stays active). Next was getting this all to fit and look clean.
First order of business was to convert the packs down to 4 cell. I had to pull the banding, re-bend, drill new screw holes in the straps and bolt back together. This took the most time. For two packs, this resulted in doing this 16 times.
Now down to 4 cells
Plastic ammo box. Nice thing about this is the sides are square versus tapering like many boxes do. Also being plastic, I wasn't worried about any conductivity from the box.
They came with inner trays which I cut down to use between the cell terminals and BMS/cables
Here it is fitted. Worked good.
Shiny BMS!!! Thanks @OverkillSolar
3/8" battery lug terminals
Getting all of this to fit. It is snug and everything has to be routed correctly but it works!
Wiring connected. Main positive is 4ga and the 3 common wires off the BMS go into a 4ga cable. Temp sensor drops down into a hole between the cells. BT module is taped down. The discharge cutoff switch wiring is routed up the positive lead to the switch. I used some high density packing foam to fill the gap between the cells and box at one end. You can just see the white peeking out in the lower left corner. Cells do not move.
All closed up, terminals ready to connect and disconnect switch works well. Need to label it.
Very happy how this turned out. Very clean and serviceable. Just need to duplicate this to bank #2.
Amazon link to ammo cans - https://www.amazon.com/gp/product/B0000CEZ8O/ref=ppx_yo_dt_b_asin_title_o08_s00
Amazon link to terminals - https://www.amazon.com/gp/product/B07PQQ928V/ref=ppx_yo_dt_b_asin_title_o00_s00
Hope you all enjoyed checking out my project and it inspires others to try building your own pack.
I set out to build a full 12v pack that was functional, looked clean and serviceable. I did not want the end results to look hacked together. After measuring the size of the cells, I worked to find a suitable housing for them and the BMS. For the BMS, I ordered from @OverkillSolar a pair of 120A BMS's with BT and these are the new models with the shut off switch for the discharge side (charge side still stays active). Next was getting this all to fit and look clean.
First order of business was to convert the packs down to 4 cell. I had to pull the banding, re-bend, drill new screw holes in the straps and bolt back together. This took the most time. For two packs, this resulted in doing this 16 times.
Now down to 4 cells
Plastic ammo box. Nice thing about this is the sides are square versus tapering like many boxes do. Also being plastic, I wasn't worried about any conductivity from the box.
They came with inner trays which I cut down to use between the cell terminals and BMS/cables
Here it is fitted. Worked good.
Shiny BMS!!! Thanks @OverkillSolar
3/8" battery lug terminals
Getting all of this to fit. It is snug and everything has to be routed correctly but it works!
Wiring connected. Main positive is 4ga and the 3 common wires off the BMS go into a 4ga cable. Temp sensor drops down into a hole between the cells. BT module is taped down. The discharge cutoff switch wiring is routed up the positive lead to the switch. I used some high density packing foam to fill the gap between the cells and box at one end. You can just see the white peeking out in the lower left corner. Cells do not move.
All closed up, terminals ready to connect and disconnect switch works well. Need to label it.
Very happy how this turned out. Very clean and serviceable. Just need to duplicate this to bank #2.
Amazon link to ammo cans - https://www.amazon.com/gp/product/B0000CEZ8O/ref=ppx_yo_dt_b_asin_title_o08_s00
Amazon link to terminals - https://www.amazon.com/gp/product/B07PQQ928V/ref=ppx_yo_dt_b_asin_title_o00_s00
Hope you all enjoyed checking out my project and it inspires others to try building your own pack.
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