Nickel fuse sheets + busbars

[harrisonpatm]

Still in the planning stages of my big powerwall, working out the details. I was leaning towards 24p packs using 4x6 cell holders and I like the nickel fuse sheets from Battery Hookup. So one side positive, one side negative, daisy chain them to get my series connections, yada yada... My question is, for people who have used the fuse sheets, how do you attach busbars to either side of the pack? If it was me, I would spot weld both sides, shape my copper busbars to fit in the spaces in between, touching the nickel directly in between the cells. Then solder them to to the nickel at 4-8 spots on each face.

Sound good? Does anyone have pictures of their setup using those sheets, for inspiration? Thanks!

 

[OffGridInTheCity]

My question is, for people who have used the fuse sheets, how do you attach busbars to either side of the pack? If it was me, I would spot weld both sides, shape my copper busbars to fit in the spaces in between, touching the nickel directly in between the cells. Then solder them to to the nickel at 4-8 spots on each face.

Sound good? Does anyone have pictures of their setup using those sheets, for inspiration? Thanks!

Here's a really nice overview of building a pack in the vein you're thinking. @hbpowerwall (one of the founders of this site) has had much experience and this youtube was one of the later ones showing a skillful build. At around 12:30 he solders the buss to the nickel sheets.

View: https://youtu.be/PenPYwa00CA

 

[harrisonpatm]

Perfect, thank you. Pretty much what I had thought to do, so nice to see someone with experience confirming it. Appreciate it.

 

[hbpowerwall]

Done again I would solder first then spotweld..

 

[cak]

I also build similar packs and my two cents would be make sure you have a high powered soldering iron. At first I was trying to do it with my cheap 60w iron and that was not working at all. Now I have a 150w iron and it works alright although I burn through tips a lot. Using large guage wire, 4awg solid core, it soaks up heat and moves it away from your work area very fast. My packs I actually buy the battery hookup 1 row extra wide which gives me a nice tab to weld onto my busbar. I also do 5x20 100p packs. Photo is what is looks like right before soldering on the wire busbars.