Precedent 2008.5 DIY Lithium build

[Bbbbrass]

BH is pretty good, and 90% of the cells are fine. It's just a better pack to take it down to the studs. I would be fine going AliExpress from one of the more trusted stores/brands, as long as I order 2-3 extra cells and can wait, and have an enclosure with compression.

[Bbbbrass]

More progress.

PO had roughly hacked a hole in the dash for some kind of voltmeter. That will be useless to us. The wonderful AiLi shunt meter is going in. Best $40 meter you can get! (Be sure to get the 350A option) This is so renters can see their battery displayed just like on their phone. The BMS BT meter I have found to be pretty accurate, but it's nice to have both.
https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1
New meter isn't a perfect fit, not sure I can save this hole. Owner is crafty and will try auto body epoxy if needed.

[Bbbbrass]

Old PD/OBC charger and port need to go to make room for the new 120 port and cover. While we are at it, let's clean up some wiring and make the dash ready for new 12V accessories. Who ran this headlight wiring straight under the cart????

That brings us up to date!

[Bbbbrass]

A little peak behind the curtain of the battery construction.

Step 1: Remove cells
Step 2: Inspect for any physical damage
Step 3: Check initial voltage, make sure above 2.0
Step 4: Test internal resistance, needs to be between 1-4millOhms
Step 5: Charge to 3.6V (Can be done in batches of 6 in parallel)
Step 6: Discharge to 2.5V (Headway would go to 2.0, we won't)
Step 7: Record cell capacity, using only cells above 7Ah
Step 8: Recharge to 3.2V, 3.6 when ready to build pack.

[Bbbbrass]

A rough sketch of electron flow. This terrible diagram does not show actual placement, fusing, or scale.

[jasonojordan]

Originally Posted by Bbbbrass

Progress made:

Discovered an upgraded(ish) motor from previous owner, Admiral MOT-A2. http://https://www.revolutiongolfcar...or-club-car-iq
(Random links from sites I don't know that have more details. Support BGW sponsors!)
https://evdrives.com/admiral-mot-a2-...lus-precedent/

Solenoid is only 2 years old (was installed by current owner).
http://https://www.albrightinternational.com/products/su60/"]http://https://www.albrightinternational.com/products/su60

Stock Curtiss IQ controller. (Sorry for blurry pic) I've never had to do an OBC bypass/removal. Looking forward to it! http://https://www.ultimatecartparts...CON-CT203.aspx

Tub needs to be cleaned.

Dagnabit, I still can't get the hyperlink tool to work!

Make sure you are deleting and not putting the https in front of the links you are using the link tool with. They seem to work when you delete the https from the front of your broken links.

[Bbbbrass]

I'll try that. thanks!

[Bbbbrass]

So, we have reached project completion! I lagged in taking photos as I finished in a one-day marathon with the owner there to provide help and input on layout. We discovered the 2008.5 precedent seat will not allow the SuperBeast cases to be on their side, so now they are flat. This makes access much easier, but makes it impossible to have an underseat storage compartment. Balancing and testing the cells individually took forever (only 2 discharge testers), and life got busy. If you have known good headways this can go much faster. One of the packs I got had cells that tested at over 90% capacity, the other averaged 83%. The loose cells were all near or above 100%! Of the 116 total cells tested 3 were unusable, and 8 were below minimum specs.

I need to get more photos, but here is the finished shot.