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The assembly kit I used is not a Vruzend kit and the design is different. The spacers go on the cells first, and then you lay the strips and bus bars on the cell terminals, then you plug in the springs to the end caps and fix them on to the spacers. Here is a link: Nishi Assembly Kit The only...

Haha these are not Lego packs that's for sure 😆 Now that I have built and dismantled the pack number of times, I've got a sense of its limits and the correct way to build the pack with the assembly kit. BTW the assembly kit and cells I used are locally made and are not renowned brands, but I'm...

Well, I guess I've been through all the mess possible while building a battery pack. My latest addition: The root cause of the contacts issue is that the spacers and the strips get mis-aligned after fixing the end-caps with a mallet hammer. While hammering the end-caps, some of the spacers drift...

Thanks again for sharing the study. I had glanced over it earlier, but read it with more focus this time around. An excerpt from the Study: The spread in my battery pack for individual cells is actually just under 40% not 63%. Now, as per the study to increase the lifetime of my battery...

The need for attention and presense of mind cannot be stressed enough. Some more goof-ups from me: I decided to build a 13s2p, 48 volts 4.4 ah battery made of same cell type (18650 Li-Ion, 3.6 volts, 2200 mah) and manufacturer. I contacted the manufacturer for the cell data sheet - didn't get...

Thanks for all your advice. Most manuals are not user-friendly and are loaded with technical jargon. I feel that manufacturers need to adopt a new approach to technical writing by including videos, images and animations to make it more understandable. IMO Discussion forums like these and online...

The fact that a balance charger can measure internal resistance, along with other features is a real bonus. It has the option of charging various types of rechargeable cells as well which might come in handy. Balance charger will be used sparingly and only while building battery packs. Once I...

Let's say I need to charge the battery pack without having to disassemble the kit. Can this be done using the balance charger: SkyRC IMAX B6 V2 60W 6A Charger/Discharger 1-6 Cells. https://www.skyrc.com/Charger/iMax/b6v2 Case 1: With end caps and strips removed, I connect the 2 pin charger to...

Yes, will check for internal resistance this time around even if they are from the same manufacturer, since I have no idea if all of them are from the same lot. Battery technology is advancing rapidly, so it makes sense to verify all the parameters before connecting them. As for buying from the...

Ok so after knocking off the old 10x2400mah mismatch cells, now I can't get the 10s2p configuration to work with the new cells. After some troubleshooting seems like the BMS failed once again! Spoke to the vendor who says its in standby mode 🙄. Returning the BMS to the vendor. Please watch the...

Well, now I'm really missing a balance charger. If I had one, I can confirm that the individual cells, and the battery pack are charging and discharging fine. There are some rare cases of the throttle getting disconnected, which can lead to similar issues. I have verified the throttle and...

I will redo the battery pack as a 10s2p pack with the new set of cells and check. I suspect a contact issue, since the reading on the ebike voltmeter and my multimeter match, doesn't look like a meter issue. My first suspect was the BMS, but now that the vendor has assured me about the...

I use a robust multimeter while building battery packs to measure the voltages. The voltmeter on my e-bike is fixed, and is essentially my only charge indicator while riding. I use my smartphone on a mount to measure speed, distance..which don't need an interface with the controller. My old...

I did some research about the pros and cons of BMS, and initially decided not to use a BMS, and buy a balance charger instead, since I was building a modular pack, the option to add a BMS later was always open. Just reading about Balance Charging, the setup and configuration made my mind so...

My e-bike got phased out in a couple of years. There are many better models available today for the same price. My only bragging rights are magnesium alloy wheels and it's a foldable 26er. My vintage e-Bike has a voltmeter as a charge indicator, an awkward looking large controller and a 36 volt...

Thanks that's even better for an affordable price too! The hobby charger models I checked initially were more expensive for some reason. I got thrown off by the 3s/4s/6s ratings of some hobby chargers. If the current battery fails too soon, then probably my next battery pack will be one with no...

@Sierratim much appreciated! I was about to settle for an inexpensive but complex method of buying a 1 ohm resistor and calculate the internal resistance manually by recording the voltage drop. This tool is just what I've been looking for! 👍

Yes indeed, I read about higher mah cell counter balancing the other lower mah cells when connected in parallel which gave me the confidence to try this configuration. Not sure what Michah's book says about this though. Here is a useful video that explains parellel charging: Parellel Charging...

Thankfully, I got my old battery pack disassembled from a professional. 😅 I verified that all the old cells were fine before using them in my reconfigured battery pack. I still have the other 10 working cells stored in a safe place.

I will be more descriptive in the future, I condensed my post to get opinions about mixing cells, however now I understand that there could be a wide range of other issues not related to the cells. I did read a bit about contact issues in vruzend kits, but I verified all the contacts were fine...