HPR3816: Post Apocalyptic 4s5 Battery Pack

HR000000000
H Hybrid: Denotes some prepurchased or hard to find components
R Robotics: suitable for robots

buy: 4s 40A BMS
https://www.aliexpress.com/item/4000025857655.html (can't specifically vouch for this vendor, just chose the first that came up)
make sure to choose 4s and balance

1. find or buy materials: duct or gorilla tape, trashed computer dvd or cd drive, 20 18650 cells, molex connectors(you can also use barrel jacks or whatever you want to transfer power), wire and maybe 'tab wire' https://nl.aliexpress.com/item/32650006768.html

2. solder everything together as per schematic and pictures (there is theoretically a danger in soldering cells, but I have never had a problem. Have a pair of pliers and a nearby window handy to throw them out of if anything goes wrong)

3. wrap in cardboard and tape as per pictures

4. add the cd/dvd drive lids(if you taped well you won't short anything and burn your house down

5. tape dvd lids to battery

Getting into the battery for maintenance just requires a utility knife.

Watt Hour does a great job describing the 3s BMS, which is very similar to the 4s used in my case: https://yewtu.be/watch?v=QNENyu97w2A

Battery Schematic

Click the thumbnail to see the full-sized image

Cut through tape to reveal battery

Click the thumbnail to see the full-sized image

Flat metal holds cells together

Click the thumbnail to see the full-sized image

Detail of 4.2v

Click the thumbnail to see the full-sized image

Only have to desolder one side

Click the thumbnail to see the full-sized image

New cells in

Click the thumbnail to see the full-sized image

Make sure there is thick tape covering battery

Click the thumbnail to see the full-sized image

DVD drive case for stability

Click the thumbnail to see the full-sized image

Tape the DVE case to battery

Click the thumbnail to see the full-sized image

Charge board with Molex connector

Click the thumbnail to see the full-sized image

Outdoors 1

Click the thumbnail to see the full-sized image

Outdoors 2

Click the thumbnail to see the full-sized image

Comments

More Information...