You're spot on, Dogman!! Thank you for the absolutely justified concern about battery fire and safety. Actually, that's part of what is driving this research.
What I am thinking about is encapsulating battery and BMS in rectangular or square aluminum tubing of various dimensions from 2" to 5" on a side, with tube ends capped and only connectors and indicators visible. Batteries would be cushioned with thermally-conductive padding, cut off (almost completely) from oxygen sources, and fully mechanically protected on all six sides by the 1/8" 6061 aluminum. The batteries themselves would not be altered in any way.
It appears that most or all lithium RC batteries, whether Turnigy or Zippy or another brand, are sold with +/- electrical leads and a multi-wire balancing information lead (which I presume carries information on cell voltage). To the best of my understanding, all the smarts of balanced battery recharging are held in the external charger (e.g. the 1010B), which receives its power from a DC power source (an AC or DC converter usually), and then connects to the battery(ies) via recharge cables and balance info wires a la:
But this makes for a very messy recharge environment.
So I am trying to make it more like AllCellTech's
which connects very simply to a standard lithium battery charger and presumably handles all balancing with smarts contained in the battery pack itself.
Does that make any sense? I like the AllCellTech batteries and will use them more, but want an option for a hard exterior protective case that has a size which the AllCellTechs will not fit into.