Custom Fighters - Custom Streetfighter Motorcycle Forum banner
1 - 20 of 365 Posts

·
Skunk Fighter
Joined
·
1,729 Posts
Discussion Starter · #1 ·
It's not hard. Most of the hardware can be found online for less than 40 bucks. I found the cells for $5 a piece. I just ordered more cells to build another pack for my track lady. Most of this information has been generously generated by the RC hobbyist. A lot of those guys build extensive battery packs.

The A123 4 Cell pack (12 volt) was plenty for my SV650. I used a 60W Iron with a temperature control box. I soldered at 600F. My 60watt box goes up to 896F. It worked without a problem. The solder works best if you have a fat tip. They are a few bucks at the electronic store. (Fry's for me)


I already had some Gorilla glue in my tool drawer so that worked to glue the linear side of the batteries together to prevent them from moving.



# Nominal voltage: 3.3V
# Nominal capacity: 2.3Ah
# Core cell weight: 70 grams
# Internal impedance: (1kHz AC) 8 mΩ typical
# Typical fast charge current: 10A to 3.6V CCCV
# 70A continuous discharge
# 120A, 10 sec pulse discharge
# Cycle life at 10C discharge, 100% DOD: over 1,000 cycles


It only takes 5 seconds to melt the solder.

Here was my cost.

Cost $5/ea Cell
Shrink Wrap $1.50
Battery 8 gauge cables $1.50 + Terminals $1.50 (local car audio store)
Battery bars $0.99
Total: $25.50

I have a lot of shrink wrap and 2 cells left if anybody wants to buy them. $11+shipping (let me know)









8 cell pack (Jacked from R1 forum)


The battery bars can be made by anybody. This is just an example of Hyperion making battery bars. I found a pack of ten the other day for a $1.

DEANS - IDK maybe thats the name of the guy that made the bars.




Videos:



It's really fucking easy.

"When in doubt just google it." :D

Update:
Note there are a few cock blockers on the thread. I already know that you know this is a home made battery pack. I dont need to warn you that you need the right tools to accomplish this small task. Obviously anything we do at home we are responsible for our own liabilities.

I just bought a set of A123 batteries for $4 bucks a piece on ebay. So if you look diligently you will find deals. The small roach clips I got them at an electronic store for $3 bucks a pack.

Charger: Venom they are about 40-60 on ebay. The refurbished charger is okay.

 

·
Perpetual Project
Joined
·
3,695 Posts
Excellent, thanks for posting that I've been meaning to look into making those, a couple of them would be usefull, for my bandit and for the cafe conversion I want to do for my 250
 

·
Ridin' Dirty
Joined
·
6,773 Posts
+rep, Good info man.
 

·
Newbie
Joined
·
182 Posts
It's not hard. Most of the hardware can be found online for less than 40 bucks.

..............

BTW try to get a really hot iron. I bought a cheap iron and had a difficult time soldering my points. If you dont have a good HOT iron you will just sit there trying to melt the solder on the batteries and eventually damage the batteries. Make sure you have a super hot iron to melt the ACID core wire. Of course I wasnt going to sit there and damage my batteries. My wire's melting point is set at 450 degrees F.

..............

It's really fucking easy.

..............
The price is much more than the $40, when you factor in the additional TOOLS, (high heat soldering gun), and time. Most people only have 25 watt soldering irons. You want at least a 100watt soldering iron, and a 400 watt soldering iron would be even bettery.

I just wanted to mention that no battery manufacturer recommends soldering to their cells.

You may not see it, but every cell that has been soldered is damaged internally. The high heat of the soldering flows through the aluminum and into the cell where it vaporizes the lithium into lithium gas. Soldering the batteries also risks soldering the Over Pressure Release Valve (OPRV) shut, causing a danger for explosion since you've now disabled the manufacturer's built in safetey mechanism. See Speedcell's notice.

Suppose your high power soldering iron costs $40, that brings your total costs to $80. That is still $10 more than my 4cell unit (shipped!), AND you still have to spend an hour putting everything together.

I have over $1500 worth of tools and equipment to properly assemble these batteries. In addition to the warranty, you get my expertise. All of my cells are built with a Capacitive discharge welding, an manufacture approved process.

I have also assembled more than six units for people who initially thought that they could build it themselves, but in the end it was not worth their time and effort.

The picture below show's my $70 4cell unit on the right:



And here's a parts list of what you get for your money:

 

·
Skunk Fighter
Joined
·
1,729 Posts
Discussion Starter · #7 ·
The price is much more than the $40, when you factor in the additional TOOLS, (high heat soldering gun), and time. Most people only have 25 watt soldering irons. You want at least a 100watt soldering iron, and a 400 watt soldering iron would be even bettery.

I just wanted to mention that no battery manufacturer recommends soldering to their cells.

You may not see it, but every cell that has been soldered is damaged internally. The high heat of the soldering flows through the aluminum and into the cell where it vaporizes the lithium into lithium gas. Soldering the batteries also risks soldering the Over Pressure Release Valve (OPRV) shut, causing a danger for explosion since you've now disabled the manufacturer's built in safetey mechanism. See Speedcell's notice.

Suppose your high power soldering iron costs $40, that brings your total costs to $80. That is still $10 more than my 4cell unit (shipped!), AND you still have to spend an hour putting everything together.

I have over $1500 worth of tools and equipment to properly assemble these batteries. In addition to the warranty, you get my expertise. All of my cells are built with a Capacitive discharge welding, an manufacture approved process.

I have also assembled more than six units for people who initially thought that they could build it themselves, but in the end it was not worth their time and effort.

The picture below show's my $70 4cell unit on the right:



And here's a parts list of what you get for your money:

The get fuck out with the cock block. Most of us have our own tools. My 25 dollar 4 cell works fine on my bike. I wouldnt fucking pay more than $40.

BTW thats why you got shit talked on WERA fucking ***.

http://forums.13x.com/showthread.php?t=243197&highlight=A123
 

·
Newbie
Joined
·
182 Posts
The get fuck out with the cock block. Most of us have our own tools. My 25 dollar 4 cell works fine on my bike. I wouldnt fucking pay more than $40.
I'm am sure everyone here has tools, that's not important. What's important is having the proper tool to do that job.

What's even more important is providing people with right information, the risks, and the alternatives they have to choose from.

As for "making our own shit", I have the ONLY fuel injected SV650 with a single sided swingarm in the world, though I'd hardly call it "shit".
 

·
Skunk Fighter
Joined
·
1,729 Posts
Discussion Starter · #10 ·
I'm am sure everyone here has tools, that's not important. What's important is having the proper tool to do that job.

What's even more important is providing people with right information, the risks, and the alternatives they have to choose from.

As for "making our own shit", I have the ONLY fuel injected SV650 with a single sided swingarm in the world, though I'd hardly call it "shit".
That's why towards the end of the thread if in doubt just google for answers. Most of us on this board make our own stuff, unless it has to be machined. Even if that there are guys on here that work in shops that have access to type of very expensive equipment. Take your fucking capitalist lame mentality somewhere else. This is Custom Fighters! I am a fucking jew when it comes to buying shit.

:LolLolLolLol:
 

·
No-U-Turns Show
Joined
·
2,615 Posts
Ahh quit the debate guys, this is a great info thread..leave the bickering to the bitch section. ;)

One thing I would add is that the hyperion bars can be a bit better because they arch up over the cell and can be less prone to arching.

here is a link on where to get them
http://www.aircraft-world.com/shopexd.asp?id=5085

they used to sell the bigger ones but changed because people were plugging up the vents in the batteries with solder

The little hole in the top of the battery is the vent..dont plug it up! :D
 

·
Newbie
Joined
·
182 Posts
That's why towards the end of the thread if in doubt just google for answers. Most of us on this board make our own stuff, unless it has to be machined. Even if that there are guys on here that work in shops that have access to type of very expensive equipment. Take your fucking capitalist lame mentality somewhere else. This is Custom Fighters! I am a fucking jew when it comes to buying shit.

:LolLolLolLol:
Is that why we're not getting along? You're a Jew and I'm Catholic?
:LolLolLolLol:
 

·
Ridin' Dirty
Joined
·
6,773 Posts
Holy shit Mavyrick, relax, no one is stepping on your feet. :doh:


We are intelligent people, (for the most part), and understand the risk/benefits/cost of doing something ourselves vs. buying an experienced person's unit with a warranty, etc.



So, thanks again to stephen for posting good info.
 

·
Member
Joined
·
606 Posts
lets be fair here, there is definitely a risk of damaging the cells while soldering. I don't think it is unreasonable for maviryk to point out the advantages of how he makes them. Welding IS the correct, manufacturer approved method of building these batteries.

Now we have some instruction on how we can DIY, we know the risks of diy and the benefits of buying one allready made. Now, anyone have any other tips on building them?

Here's one, you can buy the quick disconnects cheap on ebay. They are listed as fork lift battery quick disconnects, made by anderson, I think. I haven't added quick disconnects on my batteries yet, but I have thought about it :)
 

·
Ridin' Dirty
Joined
·
6,773 Posts
lets be fair here, there is definitely a risk of damaging the cells while soldering. I don't think it is unreasonable for maviryk to point out the advantages of how he makes them.
+1, but the way he approached it was pretty dick.





So help me understand this guys...

Difference between using "capacitive discharge welding", and a high powered soldering iron, is just that we will degrade the lithium some because of the heat applied, right?

Stephen and Emanarasi, how long have you guys been running your homemade units? How are they holding up?

What was the wattage of the soldering irons you used?
 

·
Skunk Fighter
Joined
·
1,729 Posts
Discussion Starter · #19 ·
+1, but the way he approached it was pretty dick.





So help me understand this guys...

Difference between using "capacitive discharge welding", and a high powered soldering iron, is just that we will degrade the lithium some because of the heat applied, right?

Stephen and Emanarasi, how long have you guys been running your homemade units? How are they holding up?

What was the wattage of the soldering irons you used?
Yeah I am not here to talk to shit to anyone. If I was a dick I would have posted something on his for sale threads saying what a fucking rippp, but that would just be plain gay. To each their own. I have been running my battery pack since I posted it on my build thread. Probably about a month. I haven't had any issues with the simple parallel pack. These are the same batteries used in RC's, and DeWalt packs.
 
1 - 20 of 365 Posts
Top