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  1. S

    18650 battery Kit development and discussion[testing done]

    Thanks for the bumps. As mentioned in our private emails, so far so good with the builds. My wife and I have put many miles/charges on the three packs I've completed with no problems. I've two more (10s4p) builds in progress using the simplified procedures outlined in my last posts...
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    Sounds like it could prevent an "oops" moment. The potential product liability is why I never pursued making kits. Too bad, the packs are really simple to build and maintain.
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    I don't use any thread locker. The Nylon or PVC that I make the spacer bars out of grips the screws grips the screws very tightly..
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    Hi, The previous poster asked about compression strip thickness/amount of squeeze. Here's my take after some half dozen batteries: It's not critical but you do want a definite amount of squeeze so that you make good contact. I would shy away from thick rubber/foam and stick with the 1/6" Poron...
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    Ok, Here's a way to make bus bars without much tooling. Alls required is an embossing die from a craft store like, in the US, Michaels or Joann Fabrics. The one we want comes in a package of 3 and looks like this: The dimples are spaced about 10mm apart so we want to cut off every other male...
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    Hi all, I'm about to begin my 4p batteries but I think I'll make a couple of changes to the materials I use. First, I'll use 3/16 inch PVC (I used nylon on the last one and didn't like the way the holes tapped out) rod for the spacers and 2-56 screws to hold everything together. I think this...
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    CHEAP NEW ORIGINAL 18650 21700 BATTERY CELLS, POUCHES AND PACKS

    I'm afraid that tumich doesn't know much about customer service and that's what has lead us to this sorry state. A buyer informing a seller that, in the buyer's opinion, something is wrong with the product and offering a solution is a first step in basic conflict resolution, and that's what I...
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    CHEAP NEW ORIGINAL 18650 21700 BATTERY CELLS, POUCHES AND PACKS

    I'm not sure how to bench test them and produce beautiful graphs as some can do on ES, but I can tell you this, 50 them are in a pack as we speak http://endless-sphere.com/forums/viewtopic.php?f=14&t=57810&p=1072830#p1072396, and I can assure you, they will get a real world workout from a...
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    CHEAP NEW ORIGINAL 18650 21700 BATTERY CELLS, POUCHES AND PACKS

    The cells came by sea and they took, as I mentioned, 55 days from order placement to my door. It was sort of fun tracking them using the tracking number that tumich provided. It, of course, wasn't active while the cells were at sea but after a while, the US Postal Service tracking system picked...
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    CHEAP NEW ORIGINAL 18650 21700 BATTERY CELLS, POUCHES AND PACKS

    I received 100 Panasonic cells well packaged in 55 days from order placement to my door in Atlanta, GA USA. I'm happy to receive the cells but am very displeased with the seller's performance in honoring my request for cells that had never been welded. Despite telling me that I could have cells...
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    A Gaffer Tape https://en.wikipedia.org/wiki/Gaffer_tape build. This is the most simple build that I've made yet. It's taped together....... Well, the box (sides 093, ends and top and bottom .062 polycarbonate) joints are taped up but the cell holder matrix, spacer bars, bus bars, and Poron foam...
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    It's been a while since I posted anything but I'm building a couple of 10s4p batteries and another 10s10p (as soon as the cells I ordered from Tumich ( http://endless-sphere.com/forums/viewtopic.php?f=31&t=61608 get here). So far, I've been very pleased with the builds Ive made. I've gotten a...
  13. S

    Fire at ebikes-sf

    Me too. Ilia is first rate.
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    Happy New Year!! Both batteries are holding up well but I have to say, that I haven't a lot of cycles on them yet. Here's where I get the foam: http://www.mcmaster.com/#poron-urethane-foam/=vam1d3 And, here's where I get My copper: http://basiccopper.com/10-mil-010-inch-.html . You can...
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    Holy grail of solderless 18650 is close but not idiot proof.

    Off the shelf components can be built with mostly hand tools....... only one specialist part (the dimpling block) and you are in business. Change any battery with a screwdriver. http://endless-sphere.com/forums/viewtopic.php?f=14&t=57810 KISS is best!
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    very good job! no CAD drawings, no XsSp descriptions. just plain dimples in a strip. All that's left to make a case are sides/bottom/top of polycarbonate, PVC, etc.cut to cell length plus some for compression and ditto for spacers, and ends. Again, my compliments for a job well done. Looks like...
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    Just use office-type rubber bands.... 107s are about .625 in. wide. You can trim them to width. Will work fine and you can change them out once a year. You may have to adjust (reduce) the spacer bar and side/bottom lengths a little; but not much because they are a little more dense than the poron.
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    ShA 34 sounds about right. Just remember that ability to "bounce back" is just as important as hardness. The Rogers Poron products have that property.
  19. S

    Conductivity improving grease project

    Ok Luke, here's a candidate for your conductivity improving grease. As I mentioned in this post http://endless-sphere.com/forums/viewtopic.php?f=14&t=57810, i was planning on making a "stick battery" using these star-shaped bus bars: . Here are the bars in a 10s5p battery built up on a .5 inch...
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    I don't think wire will work with this pack build. The whole concept is copper strip with dimples. I don't have any idea which route would be cheaper. You can look up thread and get some idea of what materials cost and compare that to what Batteries Plus would charge.
  21. S

    no solder battery help

    I got the spacers that I used to build the pack in the reference above from this ebay seller :http://www.ebay.com/itm/321114252941?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649. They sell them in different sizes for, I thought, a pretty reasonable price.
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    This bus bar is designed to use PVC tube (McMaster Carr Part No. 8749K61) as the spacer bar. It just fits a hole punched with a Roper Whitney 17/32 punch. I'll glue a plug into each end to secure/draw up the end plates and compression foam. Power and balance leads follow the grooves along the...
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    PM sent.
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    Die plate is .040 for .010 thick copper. It can be a little less but the important thing is that the dimple height + the thickness of the copper isn't higher than the depth of the grooves in the spacer blocks... cause that's what keeps the bus bar captured and prevents it from moving around.
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    Another No Solder/Weld 18650 Build (Updated 03/09/2014)

    Worked with both acrylic and PVC. I like PVC best because of its properties but it's a little difficult to get it in clear. Now I'm using polycarbonate because it's a bit stronger than acrylic (I knew that but I wanted to show that you can build a case with handtools by scoring and snapping...
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