Who is still building DIY batteries

[Jracine]

Due Diligence = Learning the most you can about a subject / tech prior to diving in. It's typically a 6-month (the real keen learners) to 12-month learning curve. Sorry No Instant Rice Society solution.

Very true, the best thing I've done is read. I have been reading on this site since I've joined and I'm glad I did well before I actually start to spend money and build something. This forum in packed full of information. When the time comes it will be a DIY pack.

 

[JJJJ]

Update from my other thread. Latest battery box waiting for the BMS install. Really like these new Eve cells.

 

[featherlite]

Latest battery box waiting for the BMS install

Those wire races make for a tidy installation.

I have read on this forum that copper to aluminum connections cause corrosion problems. However, some have said that Ox-Guard helps.

Online metals sells tinned copper bus bars in case you are interested.

Copper Bar | Custom-Cut Lengths | Onlinemetals.com

Online Metals carries copper bar in 110-H02. Each piece comes with a free MTR. Order pre-cut lengths or have it custom cut to the size you want.

www.onlinemetals.com

 

[timselectric]

Online metals sells tinned copper bus bars in case you are interested.

Those are tinned.

 

[Zwy]

Those are tinned.

One isn't.

I nickel plate mine if I need to make one. Even did the ones in my battery cabinet, 4 feet long, 1/4" x 1". Used a long PVC pipe and dipped half in, slowly raised it, then dipped the other half. This was after cold heading in the carriage bolt heads.

 

[timselectric]

One isn't.

Ah, I didn't see that one.

 

[JJJJ]

My indoor packs have done well. But then they are humidity and temperature controlled.

Since this may be indoors or outdoors, I do have some No-Ox-ID I might consider. In reading up on these mediums however less is more if it is used.

 

[featherlite]

Those are tinned.

Not sure what you mean by "those".

I was thinking that these are not tinned.

 

[OffGridForGood]

Not sure what you mean by "those".

I was thinking that these are not tinned.

View attachment 181202

This is a custom bus bar in that location - for turning the corner between row 1 and row 2, with the holes in the end of the bus bar.
In my DIY packs, this is where I put a fuse instead of a bus bar. {Got that tip from a member on the forum here, sorry can't recall who to give credit to on this tip.}

 

[timselectric]

Not sure what you mean by "those".

I was thinking that these are not tinned.

View attachment 181202

Correct
It was covered above.

 

[JJJJ]

In earlier days a lot was mentioned about helpful tools for building your own batteries. Here is a partial display of items I have found very helpful in the process. I’m sure others have their own tools as well.

 

[TommySr]

JJJJ, brand name of the crimping tool in the image above?



Tommy

 

[thebeavesknees]

I'm building my first pack now:



I still have a lot to learn, but, it's going well so far!

 

[Dave911]

In earlier days a lot was mentioned about helpful tools for building your own batteries. Here is a partial display of items I have found very helpful in the process. I’m sure others have their own tools as well.

View attachment 181705

Ive purchased 3 of those hydraulic crimpers. They all seem to be made by the same company. Harbor Freight, Amazon, etc.

 

[Danke]

Ive purchased 3 of those hydraulic crimpers. They all seem to be made by the same company. Harbor Freight, Amazon, etc.

That’s what I’ve noticed. Just rebranded, sometimes the only difference is the gauge and amount of the dies.

 

[JJJJ]

There are a variety of crimpers out there. A number of favorites have been mentioned over the years.

The one in the photo works well for smaller sized wires:

https://www.amazon.com/gp/product/B07QVBD6VM/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&th=1

Earlier I saw an excellent video by @HighTechLab regarding this unit. It has served me well for larger sized wires:

https://www.amazon.com/gp/product/B00ZA2P3XM/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

 

[Steve_S]

The standard Hydraulic Crimpers you get from China are in Metric / Millimeters and they work perfectly fine with Metric Wires, Lugs etc but trixy with AWG wires & lugs.
4.0mm = 12awg
6.0mm = 10awg
8.0mm = 9awg
10.0mm = 8awg
16.0mm = 6awg
25.0mm = 4awg
35.0mm = 2awg
50.0mm = 1awg
70.0mm = 2/0awg

The 70mm for 2/0 is NOT tight ! in fact you have to shave the dies a bit to make it really tight, 1mm off each side. OR you crimp with 70mm then again with 50mm to ensure a tight compressed fit BUT that leaves a pair of "wings" so keep that in mind. This also applied to the other AWG lust to varying degrees

The one I use is a Delixi 6-Ton. NOTE, The other type of crimper is BETTER than these closed models... Image showing better model also attached. There is also no need to go bigger than 8-Ton which will make perfectly airtight crimps with proper closed end lugs.


Better Model below

 

[Kornbread]

Had a pair of hydraulic crimpers from Temco for a couple years. Same place most of my large gauge wire comes from. So far, no issue with wire quality or loose crimps. TEMCo Hydraulic Crimpers

 

[Dave911]

The standard Hydraulic Crimpers you get from China are in Metric / Millimeters and they work perfectly fine with Metric Wires, Lugs etc but trixy with AWG wires & lugs.
4.0mm = 12awg
6.0mm = 10awg
8.0mm = 9awg
10.0mm = 8awg
16.0mm = 6awg
25.0mm = 4awg
35.0mm = 2awg
50.0mm = 1awg
70.0mm = 2/0awg

The 70mm for 2/0 is NOT tight ! in fact you have to shave the dies a bit to make it really tight, 1mm off each side. OR you crimp with 70mm then again with 50mm to ensure a tight compressed fit BUT that leaves a pair of "wings" so keep that in mind. This also applied to the other AWG lust to varying degrees

The one I use is a Delixi 6-Ton. NOTE, The other type of crimper is BETTER than these closed models... Image showing better model also attached. There is also no need to go bigger than 8-Ton which will make perfectly airtight crimps with proper closed end lugs.

View attachment 191858
Better Model below
View attachment 191859

I have been using the C frame type unit for many years. We used it to crimp terminals on some custom railroad equipment that is used by the Union Pacific to re-drill concrete rail ties after a derailment, to re-secure the rails. That was 15 years ago or so. They never had a problem with the crimps. That machine had a lot of 12 and 24 volt power wiring. We designed it to operate down to 32 degrees. So of course when they had a derailment in zero degree weather they ignored that and used it anyway to reopen the tracks. Unfortunately the LCD screens weren't rated to 0 degrees so they had no HMI interface. They made it work anyway. But they didn't like the open cab much. But hey, they spec'ed the machine.

 

[Tulex]

This is the crimper I purchased. They all do seem to be the same, I chose this one because it was one of the few that had both standard and metric.
Even with the standard sizes, I found it didn't seem tight enough. I tried going down a size, but didn't like the wings it left. So, I just cut strips of thin metal, I think it was flashing, and wrapped the lug and crimped it.

 

[Pappion]

This Hammer Lug Crimper worked well with a 3lb sledgehammer. Only $14.
Hammer Lug Crimper
Secure it to a bench or sizeable piece of wood.
Sometimes after a crimp, I turn it over and crimp again.
Only used it for 8awg, 6awg, and 4awg. Rated for heavier gauge.

 

[TommySr]

The one in the photo works well for smaller sized wires:

https://www.amazon.com/gp/product/B07QVBD6VM/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&th=1

JJJJ, sweet! nice price and usa stock

This Hammer Lug Crimper worked well with a 3lb sledgehammer. Only $14.

Pappion, nice price, but the 9 pairs of dies seems right for me.


truth be told I've always soldered, but now with 200Amp circuits it's time to crimp.

 

[JJJJ]

JJJJ, sweet! nice price and usa stock

I did want to confirm what @Steve_S said about the AWG conversion. Sometimes it is necessary to go to a smaller size. This can create "wings" which may need to be trimmed or knocked down, especially with the first unit I indicated.

 

[Made in North Pole]

DIY forever.

 

[JJJJ]

Here is the video created by @HighTechLab which describes proper crimping. Very nicely done. The unit they described is the second one I indicated. It worked well for my 1/0 and 2/0 cables. I only wish it came with smaller dyes.