We built a mitre box for clean cuts. 36V "D" packs go in 12" segments; "F" packs go in 18" lengths.
Drill template.
Um, drilling. Many batteries tend to get hot, and hot is bad. Airflow helps. Liquid can enter the enclosure, but it can’t collect to make trouble unless the holes are blocked.
Filing a flat for the chassis-mount connector, whose body settles into the concavity in the pack. Hint, if you were making hundreds or thousands of these, you could find a faster cleaner way to do it.
This is a Neutrik Speakon 4-pole locking connector, 30A rated, with screw terminals. Connectors are what people handle most. These scream quality. They are worth their considerable cost.
Krylon "textured shimmer" paint covers dings in the stock.
1+ = Discharge + with 25A fuse
1- = Shared charge and discharge -
+2 = Charge + with temperature fuse
-2 = Thermistor
This is how to handle charge and discharge functions for NiMH packs with a single 4-pole connector. It’s simple, clean, and prevents charging while the discharge circuit might still be open.
O, we don’t actually assemble the packs; We just specify this assembly. The cells are spot-welded together, shrink-wrapped and glued.
Final assembly.
Click. Outstanding strain relief for the charge/discharge cables. Not that you would, but you could pick up a 20-lb battery pack by the cord with this connector scheme.
Standard PVC end caps, carrying straps… all off-the-shelf parts.