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We have decided to go full-out on the van for the next 60 days or so. Galley, battery pack, shower, and some other storage upgrades are on the list. Its going to get busy. Then we should have the fall and winter to enjoy ourselves a bit before we start the job hunt again.

Decided on Orion Jr 2 with canbus. I will install a CAN to bluetooth adapter for monitoring. I think i will also use a Hall effect current sensor instead of tapping into my existing 500A shunt. The wire run to the shunt is ~6ft, and there is interference risk. I also ordered a heating pad...

Started tearing down the AC unit. The evap and controls should fit over the bed with a little work. Looks like the best cut is along this line. That leaves the compressor and fan with the condenser. The liquid line from the condenser is ~1/4" OD, then it goes to about 20...

Submitted an order for battery box parts. $175 cut and delivered in clean 16 gauge steel. Should have them in 2 weeks. I am going to cut through a floor support beam. I am not particularly worried about floor integrity. Given my load and how the box attaches. If necessary I will rivet or...

It got delayed, but the 4x4 was going to be offered with gasoline engine this year?

Getting closer. Box has been enlarged to house the class T main fuse and BMS. For ease of assembly the BMS module mounts to the side of the pack. Its tight, but I should be able to route the 4/0 cables to the fuse block and negative terminal. I am using high strand count marine wire which...

A proper BMS performs the following: Cell voltage monitoring Cell temperature monitoring Cell balancing (typically passive shunt type) Pack disconnect if the cell voltage or temp goes outside the accepted range The overkill solar BMS looks like it will perform these functions. Make note of...

Okay, just ordered material for bus bars. Plan is to sandwich the copper braid between two pieces of 1" square copper 1/16" thick. Clamp it down, then solder the edges. Its going to be a challenge to keep the wicking down I think. After that I can drill them for bolts. I am pretty close...

I was just looking at mcmaster carr and they carry 2/0 gauge braided strap which looks like the same product. I can solder a copper plate with hole, or crimp a pass through eyelet to terminate for each cell. https://www.mcmaster.com/69925K43/

Making some progress. Need to decide on how the cables will be routed, and If I want to put the main fuse inside the box. I think I will need to make some bus bars. They may need to accommodate some expansion, so I am not sure what I want to do. I could dig around for some that might work with...

Has potential. Needs a 3D mockup. Cardboard Aided Design (CAD)?

This is a good option. Inexpensive, minimal external component count, mostly programmable via bluetooth. Decent history. Since it includes low temp disconnect, and high/low voltage disconnect, it serves all the basic BMS needs. Its only 120A continuous (needs a heat sink for that I think)...

Cells are in the mail. I should have a tracking and delivery estimate next week. They provided photos of what are (supposedly) my cells, and a video with voltage measurements. Looks like they are shipping them full at 3.29V

I have a couple I am considering. Pending some details back from tech support. I will probably go with this option. Its a bit pricey, but has lots of user configurable options. I can use a OBDII to bluetooth adapter to view vital states from a smartphone. Not terribly advanced, but does the...

My plan is to assembly the pack on the bench. That will consist of buss bars, BMS leads, and the compression plates. The box will be mounted in the van through the floor, and insulated with 1/2 or 3/4" foam. The pack will then drop into the box, and strap/clamp down with some yet to be...

From what I understand, most of the effect is due to high C rates causing anode expansion later in the cycle life (2500+ cycles). Restraining the cells prevents this. I don't think I will go to 300kg though, just restrain them with maybe half that. With regards to the heating pads, My thought...

Here is the somewhat vague details on fixture vs non fixture. Looking at RV tank heating pads, this pad looks promising. Two of them will wrap the entire vertical perimeter of the cells. ~160W total, and they have an internal thermostat 45-68F approx. I would still control them from the...

I can find the spec later, but they list cycle life with and without restraining fixture. plus why specify plus/minus? I don't think I need the full preload to start with, just a fixture that can take that. The cells will expand 0.5-1 mm after a few hundred cycles, which should create the...

Mmmm, Box.

Agreed, this battery maker lists a force spec. In this case 300kg load on the pack for optimal cycle life.