New England Hybrid Festival 2013
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New England Hybrid festival 2014

Getting started on the final design and build

Getting started on the final design and build
making the buss bars

After looking over all the data and lots of other peoples approach to using the A123 batteries, I still think my original cell to cell and voltage tap concept is going to be the way I will go. If a cell fails, I want to be able to fix it, and since the pack will have a smart BMS, it will tell me which cell is bad, so I may as well put in the work up front to retain that possibility.
Started by rough cutting the 1/4"X 1/4"aluminum 6061 T6 bars to a bit longer than we need with the bandsaw.
Then in order to remove the burrs, I ran all of them through a deburring step on the belt sander.
Next I milled all of them on one side, still longer than the final length desired.
Turned them all around, and made the second side exactly the final length required.
A final deburing with belt sander, and the 110 blocks are ready to drill and tap the holes.
Next task is the cell tab punch, and a final determination as to the best screw size to use for the clamping.