Could you adjust your 20S charger to correct voltage for the 16S battery?
For example, I was able to adjust a 10S 42v kingpan type charger for use on 12S and 14S batteries.
The simulator is supposed to be a real world simulation. I get 32.7kph with 10T on 36v:
https://www.ebikes.ca/tools/simulator.html?motor=MMAC10T&hp=0&cont=C20
I don't mean use a screwdriver as a screwdriver. What you can do is knock the upper edge on the right side with the screwdriver and hammer to turn it counter-clockwise a little at a time by giving it a few taps. It is much easier and quicker than the drilling method.
Since you did make a slot, you can now take a screwdriver and hammer and try to unscrew it by tapping on the edge of the slot at an angle to unscrew. I have done this before and it usually works.
The plug/socket on the battery may only be rated for 3 amps, so might overheat and melt.
to add: I have had a em3ev Dolphin pack and this is what Paul has said.
It is not necessary to load test separately. You can do the whole string at once with by connecting to something like a heater. I use one or two of those oil filled Delonghi ones, or light bulbs. Then periodically take the voltage of each battery and record over time to see if any are seriously...
Yes, but the lug has to fit your cable gauge exactly and you have to use a crimper with jaws made for that type of lug. Bus bar often has double row of holes for 2 hole lug.