New battery for ebike, part 2

Main positive and negative conductors are made of copper strips cut from sheet. Strip ends go trough fiberglass part where end are folded back to secure the strips in place.

Detail of balance wires and connector. Output cable is already soldered on copper tabs.

Whole battery

 

Battery housing. Intelligent BMS and all the wiring in place.

Plywood separating battery and BMS space

Cushioning of battery compartment with foam. There is fiberglass “floor” (with blue foam).

Battery fits tightly and does not move with lid on.

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