Have to give huge thanks to @LithiumGods, without his help this never would have happened so smoothly. Long story short I own a 2002 with 28 of @Inwo green cells with a BMS. My install went perfect and is still going strong. I did the same install on my friends 2014 and dont ask me how, he killed the cells. Now on to the Bolt install…
Sorry in advance for the crudeness of this tutorial, not my strong point. If you have any questions please reach out to me and I will try to explain.
Battery was shipped to me, two 10c and one 4c packs.
I joined a 10c and 4c section with all thread and placed the other 10c pack on top with toolbox liner between the packs. 1"x1/8" aluminum was used to joint the packs top to bottom through the all thread. I didnt have a piece of starboard big enough on hand so I just cut down a small piece of plywood to mount the 24s Active Balance Unit.
Each cell has 3 plastic rivets. The center rivet head was carefully drilled off to the copper plate leaving the rivet stud behind. Each rivet stud was drilled to accommodate the 3/8" stainless screw which held each balance lead. There is some removal of plastic to be able to neatly run wires under the provided plastic covers. Simply grab with needle nose twist off.
A positive post needed to be made on the 4c pack. I simply bent up a copper L from a 3/4" copper coupling. Drilled and bolted to the plastic housing of the battery.
Next I framed simple boxes and a cover for the battery compartment out of pine and plywood. Prong T-nuts were used to bolt the pack to the plywood base.
Trim down the seat reinforcement, paint up the plywood and slide it in!
Now for the numbers…you can be the judge. Inital charge with profile 116 from @LithiumGods
And a quick 10 mile run to drop the car off.