Thanks john61ct, that's the idea alright. I'm using 3/16" outer compression sheets of Phenolic sheet, which is pretty stiff,
but it's a big box so I have my fingers crossed on that.
This box is becoming a big hefty hunk of plastic, copper, and phenolic sheet, so I can't really recommend it as any kind
of design advancement,.. it's Tank pure and simple, but by jangles it's going to be strong and safe. (hope)
Compression sheet thickness shouldn't matter that much if the thru bolts are spaced right, which is the next question,...
how many? How much space can I get away with between bolts? At the moment I'm thinking 12 screws, with maybe a few
more along the end bus bars to insure full contact there, with slightly thicker Poron strips at that point.
The Poron thickness is the next unknown,.. I'd like to use a 1/4" thick sheet. But I think it crushes 25 percent at full
usable compression, so maybe I should use 3/8" thick sheet. Poron is cheaper than silicone, so I'll try that first.
When it comes down to testing the darn thing, I racked my brain for a while trying to figure out how to know if some
cells aren't making contact.
At the moment I figure; first, give it the full throttle test to see if it delivers the 1.5Kw that the other battery gave.
(13S/10P) If less.. something is wrong. (This is a 16S/11P pack.)
Then drain the cells down a bit, take the pack apart, and check for full charge cells. They will be the no-contact's.