Recently the lipo battery pack on my eMTB (15Ah 12S 2P) started to develop some issues and i decided to change it. i choose A123 battery cells for the new one. i like the life cycles ( 1500 +), the discharge rate, not like the lipos but still pretty decent, and like the abuse tolerance of this cell. http://www.a123batteries.com/product-p/anr26650m1-b.htm
For the enclosure will be using a UK 409 Dry Box, this will waterproof the system and will provide space for the volt meters, connector and series/parallel switch. http://www.uwkinetics.com/products/409-dry-box
For the assembly of the pack i like to use hot glue because once it has harden and the pack is enveloped it provides mechanical reinforcement to the structure of the pack.
Once glued and spot welded just need to solder the Discharge wires and balancing wires.
Pack specifications: Single Pack 10Ah 6S4P
One of 2 finish pack with discharge wires for parallel/series switch set up.
i really like to use the convenience of being able to charge the batteries in 6S and using it in 12S setups, just by flipping a switch without having to disconnect anything.
The instruction of the parallel/ series DPDT switch are in this post
This is the final Product:
in the Drybox i included: XT-90 loop key 2 Volt meters with alarm 2 on/off switches for the volt meters XT-60 charging port 2 balancing ports DPDT switch for charging (6S) and discharging (12S) configuration.
not visible in the pic. is the Ubec and 2.4Ghz transmitter.
all this is installed in a ABS enclosure inside the DryBox.
The wires i used Flat braided wire equivalent to 12 AWG to run it under the bindings. the look it’s more clean.