Nodge68 said:
10mm is enough Ali.
Your power unit won't move that much, as long as you have the tie bars located.

I like that installation, it looks neat and tidy. ;)
Click to expand...
Thanks mate, I think I'm getting closer to the maximum number of battery modules possible under the bonnet. Ten 11.2kg modules a fair bit.
I've come to the conclusion VW picked overweight, oversized battery modules to compensate for zero cooling or heating.
This is good as I don't need to worry about those things but not so good as they take up a LOT of space and are heavy.
 
Alibro said:
Thanks mate, I think I'm getting closer to the maximum number of battery modules possible under the bonnet. Ten 11.2kg modules a fair bit.
I've come to the conclusion VW picked overweight, oversized battery modules to compensate for zero cooling or heating.
This is good as I don't need to worry about those things but not so good as they take up a LOT of space and are heavy.
Click to expand...
I'm curious as to what cells are in the battery modules?
I'm guessing that pulling one apart to see isn't really financially a sensible move?
 
Jayridium said:
Looking good bro.... Out of curiosity, how did you measure the under bonnet clearance?
Click to expand...
I refitted the bonnet and looked with a torch. I have the radiator out atm so it's easy to see. ;)
Nodge68 said:
I'm curious as to what cells are in the battery modules?
I'm guessing that pulling one apart to see isn't really financially a sensible move?
Click to expand...
LOL, not really, either financially or safely. :D
They have three pouches per cell enclosed in strong plastic
 
Were you over here, I'd say take a battery module to one of Aberdeen Airport's helicopter terminals, and bluff your way to security, pretending to be on the flight to whatever rig you read from the board, then they would xray your bagage, you'd remove your laptop from one bag, the battery from another, they could swipe it through an Xray tmachine, ask them nicely and they might do it again from a different angle. Once it's been x-rayed, "answer your phone" to "take a call from your boss" and exit stage right "trips been cancelled".

I know that sort of "real life hustle" would take a bit of a brass kneck, but what can I say, I regard brasso as a skin care product :rolleyes:

If you managed to bluff them into Xraying it from a couple of angles, say top down, side on, and screen shot, or photo the screen of the xray machine and I could do some digital witchcraft to dimension up the gubbinses inside the module, then armed with approximate dimensions of ths cells, I'm sure you lot could identify them.

Would a royal mail sorting office have an X-Ray machine? What about a Veterinarian? Or a Dentist? Or a NDT place? Or customs at the ferry terminal?
 
Alibro said:
They have three pouches per cell enclosed in strong plastic
Click to expand...

So they're just 3 pouch cells in series per module? Is that a large module or small module?

I'm just thinking out loud here, but is it possible could they not all be separated from there cases into individual pouches and be put into a larger box altogether, like they are in the Jag I Pace?, although that battery pack is liquid cooled.

Maybe it's better and safer to keep the packs as they are? Ignore the ramblings of a crazy man.:oops:
 
Jayridium said:
Were you over here, I'd say take a battery module to one of Aberdeen Airport's helicopter terminals, and bluff your way to security, pretending to be on the flight to whatever rig you read from the board, then they would xray your bagage, you'd remove your laptop from one bag, the battery from another, they could swipe it through an Xray tmachine, ask them nicely and they might do it again from a different angle. Once it's been x-rayed, "answer your phone" to "take a call from your boss" and exit stage right "trips been cancelled".

I know that sort of "real life hustle" would take a bit of a brass kneck, but what can I say, I regard brasso as a skin care product :rolleyes:

If you managed to bluff them into Xraying it from a couple of angles, say top down, side on, and screen shot, or photo the screen of the xray machine and I could do some digital witchcraft to dimension up the gubbinses inside the module, then armed with approximate dimensions of ths cells, I'm sure you lot could identify them.

Would a royal mail sorting office have an X-Ray machine? What about a Veterinarian? Or a Dentist? Or a NDT place? Or customs at the ferry terminal?
Click to expand...
LOL, you sure your not a double 0 or somesuch?
 
Nodge68 said:
So they're just 3 pouch cells in series per module? Is that a large module or small module?

I'm just thinking out loud here, but is it possible could they not all be separated from there cases into individual pouches and be put into a larger box altogether, like they are in the Jag I Pace?, although that battery pack is liquid cooled.

Maybe it's better and safer to keep the packs as they are? Ignore the ramblings of a crazy man.:oops:
Click to expand...
They are three pouches in parallel and four in series or two in series for the smaller modules
I had thought of separating the spare ones to use in a moped or 125cc bike or even a lawnmower to get a higher voltage per module but for a car I'll leave them as they are. ;)
 
Nodge68 said:
Ok so 4S/3P for the large, and 2S/3P for the small.
That makes sense, but must be a PITA to work out the BMS lines. :(
Click to expand...
It was. :confused:
I have all that figured out already so just pushing on with fitting the modules.
If I do decide to separate the parallel cells in a few spare modules it would give 12S or 6S depending on the module, or if I wanted more power then 6S and 3S.
Either way I could build a very sweet leccy motorbike with a decent range. :p
 
Alibro said:
LOL, you sure your not a double 0 or somesuch?
Click to expand...
If you remember that I worked on oil rigs for years (used to be rigs now I work on boats) the helicopter side of things becomes less impressive, and as for the brazen brass kneckery - what can I say, I'm almost weegie...
 
Alibro said:
It was. :confused:
I have all that figured out already so just pushing on with fitting the modules.
If I do decide to separate the parallel cells in a few spare modules it would give 12S or 6S depending on the module, or if I wanted more power then 6S and 3S.
Either way I could build a very sweet leccy motorbike with a decent range. :p
Click to expand...
Pouches? Are these LiPo or Li-ion?
 
Alibro said:
That explains a lot. :p

Li-Ion
https://www.secondlife-evbatteries.com/products/vw-egolf-15v-samsung-sdi
Click to expand...
It's interesting that the cells are Samsung, and have a 108 AH rating.
I've been looking the the Hyper 9 as a possible power unit for my Avenger (I know I could sell it, but I'm wondering if converting it to electric might be a better option), because of the lower voltage that motor needs, and its air cooled.
For a DIY conversion where the batteries are expensive, it is handy to know what the VW cells are rated at, and looking at the prices, they're not that expensive when you consider the Hyper 9 needs just 8 modules in series. I'm not sure what the maximum current capacity of the VW cells are, but one would like to they they have a 10C maximum discharge rate, but I suppose it makes sense to have 16 VW large modules in a series parallel configuration, giving 216 AH at a maximum of 134.4 Volts.
Definitely a possibility for use in a low voltage EV conversion though, in preference to the more popular but more expensive CALB or LG CHEM packs often used with the hyper 9 motor.
 
Last edited:
kernowsvenski said:
John, do this! Ali's work has been inspiring and if it gets you doing the Avenger up after these years that'll be a double whammy of a great output.
Click to expand...
I'm thinking about it.
The bodywork needs doing first, then I need to find the £6k it'll cost to buy the motor and batteries. :eek:
 
Nodge68 said:
I'm thinking about it.
The bodywork needs doing first, then I need to find the £6k it'll cost to buy the motor and batteries. :eek:
Click to expand...
Buy a complete damaged Leaf and it will be much less than £6k. I did it wrong but you can learn from my mistakes. ;)
 
Alibro said:
Buy a complete damaged Leaf and it will be much less than £6k. I did it wrong but you can learn from my mistakes. ;)
Click to expand...
I could do that.
My concern is the space for the batteries, as the Leaf is a 400V system, which obviously needs lots if cells to be incorporated.
This is why I thought about the Hyper 9, which is only a 100V motor. Unfortunately it's expensive, but it does come with its own configurable inverter.
I'll see, whatever I do will have to get past Mrs Nodge first. :eek:
 
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