SURRON DIY 80V / 29kW BATTERY PACK BUILD – HOW-TO
0:00 - Introduction
0:29 - Organization of This Video
1:48 - Pros - Why DIY Build a Sur-Ron Battery Pack?
3:48 - Cons - Why Not DIY Build a Sur-Ron Battery Pack?
8:44 - Nickel Strips vs. Bus Plates
10:52 - Cost Example for DIY 72V Pack
14:04 - Brief History Of The Surron Pack
19:37 - Why use 21700 cells, if the Surron is not designed for them?
20:55 - Figuring out cell layout
22:40 - Why you shouldn't glue cells together
25:50 - Finding a case - Huge problems
29:04 - Cell Holders/Spacers for 20S / 22S 9P
30:03 - Cells & Copper Bus Bars - Choosing & Finding
31:50 - Searching for Copper/Nickel Bus Bars
35:00 - Paper Insulators - Needed?
35:00 - Build Process Photos
41:30 - 45 Second How-To Build a Sur-Ron Pack
42:17 - The Actual Build Process Video!
44:55 - Best 21700 Cells to Use for a Surron Battery Pack
46:45 - Is the cost savings worth the work?
47:13 - After all the Work, $1000-$1400 For Labor Is Not Too High!
48:35 - Solving the Bus Bar Problem
53:00 - Links In Description to Buy Components
56:07 - Parts Start to Arrive, Cells Held in Customs
57:38 - Copper/Nickel Bus Bars Arrive
58:39 - V1 Metal Cases Arrive
59:00 - And, Get Ready for the Big Letdown..
1:00:30 - Next Problem... 575A BMS Doesn't Fit
1:01:50 - Finally ready to weld!
1:06:00 - 3D-Printed Case Arrives
1:08:50 - Starting to Weld
1:13:12 - Connecting the 2 Bottom Bus Plates
1:16:36 - Connecting the BMS wires
1:20:30 - Fiberglass Sheets
1:23:15 - How the Case Fits in the Bike
1:24:50 - Soldering B+ and B- wires
1:26:20 - Important Notes About ANT BMS Setup
1:28:10 - Finishing Details & Tips
1:32:52 - The Finished Battery Pack
First: Sorry this video, again, is (just a bit) long! Tried to make it as brief as possible but it covers a very involved 4-month research and build process. And, some things I repeated, sorry about that.
This covers the process of researching, finding components, and DIY building my 29kW, 80v nominal (92.4v fully charged) 22S9P high-power Surron battery pack. (Note - same steps apply if you're building a 60v, 72v, or 80v battery pack - and for the Surron or Talaria.)
There wasn't a whole lot of info about DIY Sur-Ron pack builds online, so I thought I'd document the process. The Surron pack requires some specialized parts, and is super-compacted into the available space, so it's been the most difficult pack to build of the 15 I have done since 2015. Yes, you can save over $1000 by building the pack yourself, and yes, it's satisfying to complete, but I do NOT recommend building the Surron pack as your first battery build. Do some simple packs, and study battery theory, first before trying this.
Pack Specs:
22S9P / Samsung 40T / 21700
80V Nominal / 92.4V fully charged
36Ah, 2880 watt-hours
Max 315A, 29.1 kW
COMPONENTS USED FOR BATTERY PACK:
Cells - Samsung 40T 21700:
https://www.imrbatteries.com/samsung-40t-21700-4000mah-35a-battery/
https://www.nkon.nl/ru/samsung-inr21700-40t3-4000mah-50a.html
BMS - Ant BMS 8-22S 130A Continuous / 325A Peak:
https://a.aliexpress.com/_EIsyz69
Bus Bars/Plates - Custom Copper/Nickel Bus Bars (22S9P/20S9P):
https://coolwatts.co/products/Copper-Nickel-Bus-Bar-Set-20S9P-p637710249
Cell Spacers - Custom 21700 Offset Spacers for 20S/22S 9P Configuration:
https://coolwatts.co/products/Cell-Spacer-Kit-20S9P-p637727133
Case - Metal 160x139x420mm (Fits Talaria):
https://coolwatts.co/products/Metal-Battery-Case-Talaria-p637748277
Case - Metal 160x139x420mm, Diagonal Cut Corners (Fits Surron):
https://coolwatts.co/products/Metal-Battery-Case-Surron-p637743572
Case - 3D Printed 158.5 x 136 x 422mm, Fits Surron - Free .STL Files:
https://drive.google.com/file/d/1voKeow9uXJ0DqoditUva9ZvxhWsCv5NO/view?usp=drivesdk
Welder I Used - MinderRC DH30 MAX V2:
https://a.aliexpress.com/_EJ4nVTB
COMPONENTS FOR MY 29kW FRAME-UP SURRON BUILD:
**Coming Soon
I'm adding chapters to make the video easier to navigate. If you want to skip ahead to the building process clips, feel free, I know it's long.
Feel free to leave comments and questions; I'll try to answer any questions.
Thanks for watching!
My old channel, with 72v BBSHD and Tangent Ascent videos:
CALIFORNIA ELECTROBIKE UKRAINE
@californiaelectrobikeukrai5074