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Plug Bug: Strapping Thundersky batteries together


Here’s how I strap the Thundersky batteries together.

As previously mentioned, I bought the Mini Polyester Strapping Kit 5/8″ x .040″+seals + tools for $80 (plus shipping) on ebay.

The pack of 4 (or 5) cells is squared with a regular square. Be sure to line up the terminals in the direction you want them. I ended up restrapping one cell again. Actually, I did it twice; I actually strapped it back together in the same configuration that I took it apart in (doubt!).

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Tape on the end pieces (1/8″ thick aluminum sheet). Twice I forgot to do this and had to restrap the bottom one again.

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Cut the strap with some excess:

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Put the strap in the bottom of the strap tension tool:

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I dremeled out little sections to allow the strap connectors to sit (somewhat) flush:

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Strap lined up with the tool and brought up to tension with the ratcheting mechanism:

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Clip slipped on over the slot and the crimped on with the crimper tool. After crimping, but before cut-off, I file the rough part of the edge off.

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Finished strap:

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A whole lot of cells (this is most my rear pack):

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6 Responses to “Plug Bug: Strapping Thundersky batteries together”

  1. dad says:

    hey looks quite a job gettin the batteries together – so you will be using these after all – how will it work in the back>?

  2. corbin says:

    hey dad, yeah — no backseat, like we talked about! just cells! I think it will work out best, given the additional weight it is adding to the car.

    corbin

  3. Eric says:

    How are you going to lift this pack into the car ?

  4. Eric says:

    OK, I see in sets of 4. Very nice.

  5. Rudi Richter says:

    Hello Corbin,
    It is a nice idea and I guess it will work by having lower price and weight.

    At time I am contacting Winston and Sinopoly, the former Thundersky partners splitted and got a price of 8USD for the metall stripping for volume from Winston.

    A question, do you use any curcuits to balance the cells to avoid capacity loss? I read Infineon is offering a new solution for this.

    Thank you,
    Rudi

  6. corbin says:

    rudi — i use an elithion bms.


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