made the battery today, going quicker everytime really. worked through this a few times on endless sphere, but I guess it cant hurt to do a quick picture story of the battery welding - who knows whom it might help and it will be quick for me
30 cells LG 18650HG2
added cardboard shield to prevent shorting of plus with the negative shell
cut 20x 10x0.15mm nickel strips
marked 10 of them with my knife and added flux to that spot for later serial connection reinforcement
set up solder spots. yes, its only 9 because I forgot one …
my vice, set up with 2 pieces of wood and an angle to keep cells aligned. with only 3 cells parallel, I was able to do 2 parallel packs at a time
off to welding - my fabulous stoneage DIY spotwelder - a superold battery charger, probably from WW2, directly connected to a 2F supercap. when I want to weld, I stomp on the DIY copper switch, basically 2 thick copper bars that will touch briefly. in order to avoid that they weld together, I put half a skate truck bushing between them to reliably separate after each welded spot!
it works well though - plus sides with the small pole:
and minus side with more room to work with
all 10 packs done
adding some hot glue to avoid that the shells will work on each other
then doing all serial connections. the middle of the battery by 3 nickel strips each (its not a lot, if I assume about 15A per nickel strip its just 45A, but that works for me in a max 60A continuous battery).
the “outer” connections I did with 2x 5mm wide copper wick each, because a single nickel strip feels a little too small for the typical currents
plus and minus side has a little extra copper wick to attach the battery wires - I usually go with 10AWG, but I think this time 12AWG will do. taking the isolation off, then splitting the small copper wires inside in half, putting the dual copper wick in between and clamping the split sides together.
this makes for a very nice joint after soldering
finally thick shrink tube with glue inside and bending the wire in the correct form while the shrink tube is still hot
then fixating the wires with some scotch tape and folding the battery like a butterfly. the minus wire is running in the channel made by the 20 serial connection nickel strips (that I covered with thick adhesive tape)
finally shrink tube and a quick weight check: 1500gr!
no balancing wires - Ill check back on the battery in a few months for maintenance and measure the serial packs manually. I dont expect any drift because all my other batteries also never showed any drift. but who knows, this is my smallest battery - maybe with more load Ill see some drift eventually.