Rebuilding my rebuilt rebuild pack…again.


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18650destroyer

New member
Joined
Feb 20, 2022
Messages
6
Hello,
I started building 18650 packs 2 years ago and have been trying my best to make myself reliable packs.
I started with soldering and did that for a while.
i have no problem with soldering the cells, those have always been easy, quick and reliable, I have always had trouble getting the bus bars to solder nicely even if it did stick, I always had trust issues with it, I played around with several different methods such as the amount of flux I used, how hot and how long my soldering iron was on the bars and still didn’t have luck. I even presoldered the wire using a torch.
I had a critical event about 6 months ago and had my batteries fail.
the built in fuse in the cells went out before the soldered fuses did so I decided to swap to spot welding 100% with nickel strips.
I am reusing the bus bars because I don’t want to buy more lugs and wire.
What do you guys think about the design?
There isn’t contact on every strip but I feel there’s enough to make it work just fine.
 

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OffGridInTheCity

Active member
Joined
Dec 15, 2018
Messages
2,068
Hey there. Unless I'm missing it, the thing that jumps out at me is the lack of individual cell fusing. Doesn't look like the nickle strips will burn thru easily.

I use 6awg twisted (bare) copper wire - https://www.wireandcableyourway.com/6-awg-soft-drawn-stranded-bare-copper-wire - and this solder - https://www.amazon.com/gp/product/B00DE2QVIG/ref=ppx_yo_dt_b_search_asin_title with a 100w soldering iron - https://www.amazon.com/gp/product/B002I7X7ZS/ref=ppx_yo_dt_b_search_asin_title

1656010131070.png

And have no trouble soldering things - no flux or special effort needed.

I write this to share in case it helps :)
 

18650destroyer

New member
Joined
Feb 20, 2022
Messages
6
Hey there. Unless I'm missing it, the thing that jumps out at me is the lack of individual cell fusing. Doesn't look like the nickle strips will burn thru easily.

I use 6awg twisted (bare) copper wire - https://www.wireandcableyourway.com/6-awg-soft-drawn-stranded-bare-copper-wire - and this solder - https://www.amazon.com/gp/product/B00DE2QVIG/ref=ppx_yo_dt_b_search_asin_title with a 100w soldering iron - https://www.amazon.com/gp/product/B002I7X7ZS/ref=ppx_yo_dt_b_search_asin_title

View attachment 27678
And have no trouble soldering things - no flux or special effort needed.

I write this to share in case it helps :)
Thanks for sharing what you use for bus bars, I guess I should try out how different wire sizes and strands solder.
 
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