Day More! Time to start getting things accomplished!
So I wanted something that would be durable and non-conductive, so I got a few cans of truck bed liner and started hosing it down. After getting a new piece of steel and re-designing the face plate (Class-T fuses are HUGE!!!) the test fit looked pretty good.
Wiring was a little time consuming but the neat package was going to be worth the effort. I used some threaded nylon standoffs to mount the BMS so it was electrically isolated from the case.
Waitaminute... why the F#@K are there 10 wires on an 8s BMS?!?!?
So evidently JK is stupid and can't count, so my 19v battery... Grrrr....
But I mounted the face plate on hinges for access to the guts (fuses, etc) and some welded nut tabs to hold it closed. The fans draw plenty of air through the hole in the front when the lid is on which goes around both sides of each bank and over the top, that ought to work well.
The cooling fans will be run off the existing 12v system up at the camp so it'll still cool when it's Stupid Hot and nobody's around. Cut in at 34c and cut off at 24c and tested good! The heater pads won't arrive until the end of October which is why the keen eyed observer will notice holes in the side walls and a little gap.
Next steps are to:
Replace the STUPID harness!!
Extend and mount the STUPID start switch.
Install the heating pads when I get them and get back up there.
I'll have to transport this assembly to the camp in 5 pieces, 4 shipping boxes of cells and the case itself. Looking back, I've learned a few lessons though:
Use thinner steel. I'm so used to the industrial side that I used nice "thin" 10AWG steel... the box weighs about
60lb! EDIT: Just did the math and the box is 95lb of steel alone!
Get another brand of BMS. This JK has been a real hassle!
Order parts sooner. The heating pads are 2-3 months to arrive from time of order.
Use lighter weight steel. This thing is heavy!
Mock up in cardboard first. Save money on buying extra steel plates.
Build it with THINNER METAL!!
Have the World's Strongest Man on speed dial to help move it.
Ssssoooo.. anyone want to go camping in NE Washington in a couple weeks? Anyone strong with a good back?
Final Specs:
8.5Kwh
8s 304Ah EVE cells
JK 8s 200a BMS with Heater
3x 120mm IP65 Noctua exhaust fans
Digital temperature relay
24v relay between BMS and heating pads
4x 20w 24v heating pads*
160a DC breaker
Aili Shunt
150a Class-T fuse
3.22 Metric Assload-a-grams!!
2AWG wire on positive leads
2x 4AWG on negative leads
Copper bus bars where applicable
3/8" isolating terminals
Whew! Still slightly cheaper than a Trophy or the Seplos case, AND 30% more capacity, active cooling, real shunt, heaters, built in Class-T fuse!
Hey
@Will Prowse , you want to do the teardown review? You just need to pick it up.
I think this counts as "DIY", right?