All right, it's that time again to build another battery. Let's go to the bench. All right. Following in our series of Open Source projects with our L60 cells.

These are the cells that, uh, we've been pushing for a little while and we've made this. It's a 4S battery. It's 12 volts and then we've also, uh, made a uh eight cell version, right? So what we did last time is we configured them in this position right here. So eight cells, four this for like that and what we call this configuration was a fat because it's kind of.

You know, it's kind of squarish and and fat. Uh, the other configurations that you can do are longer. so that's why this is the fat. So this is the long right.

You can also configure them like this. eight cells just uh, zigzagging all the way back and what you have to do in order to keep them at 4S you'd have to tie two of them in parallel. So two negatives here, two positives there, then connect these to to the next ones and then connect these ones to the next ones and then connect these ones to the next ones. and then the uh, other terminal is going to be here, right? So that's what we're going to do today and again.

If you're new to this series of videos, these are all open- Source projects and the reason why we can do this is because we have a sponsored PCB Way.com More on them later. All right. So let's pull up our drawing app here. Uh, what you're seeing here is the first iteration and there's several iterations uh, six to be exact that we've done.

So I'm going to show you the whole evolution of this project, right? So let's look at the 3D version of this again. The reason why I'm not showing you from the ground up is because we've drawn these before, right? Those those little four uh cell bus bars PCB projects that we've shared before I All I did was just uh, copied and paste two of those and then merged them right and then just make sure that the distance between these and these were the same and then reran uh, the copper traces and stuff right? But this is what it looks like. uh and I'm going to point out certain things like this: uh is the balancer. Let's see this is the balancer connector right? and it's right here so that you have a little cable and then you put it right here on the center.

These right here. These pads were are designed to so you can put a u a terminal block in here that is made out of aluminum and it has like uh, holes on one side that can carry up to like high quality two gauge cable and then the other side is uh four American wire gauge and then the other one's just 20 or 1 or zero gauge I think that's what some people call depending on what brand of cables it's so that's what these these exposed things are. But the thing was that once we started doing these and then and um, we started testing them, This copper traces that are here. There's one on the top here, one on the bottom.

it was just not enough to carry the 1200 amps and 800 amp continues right? So they're getting too hot. So what we ended up doing is was just designing a an aluminum plate that would go on top of this. and we realized that by just having a an E inch aluminum plate that go in there that that did the job right. So so yeah, you could, the copper helps here these two.

but then you know with aluminum plates and and so then this uh, exposed uh plate here is not no longer necessary. and so that's why we changed that. That's why there's other versions of this. Uh.

Also, this was kind of in the way when we made a custom a steel box enclosure for this battery right? and so we had to move that right. So so this is version one I think and then let's open up the other one here and then we'll see the so this is 1.2 Let's look at 1.2 there. So here's 1.2 I took down that uh I made these longer because it needed more exposed area here. When you were people that are going to use these without having uh the uh you know the the the aluminum, the terminal block here right? So if you're just going to use ring terminals then you need a little bit more exposed area here.

So that's why we did that. Uh, then I started adding these holes right here so that we could move this uh plate all the way closer to the bottom of the cell. and then we. it leaves more room on top of this PCB to put really thick quarter inch aluminum because these need to be quarter inch because all that energy has to squeeze through this area right here and then right here and then right here.

right? So so then that's why we did those holes. but those holes turn out to not be exactly the right size. They need to be elongated like these ones and so I kind of didn't see that coming and so then we had to change it. So that's why we did.

Version: Uh, what is this? Uh, 1.2 this is 1.2 Let's see what's the difference of 1.2 Let's close this one. here. Here it is I think I made this ones longer I think um I don't know exactly. The changes are minor enough here that I can't even tell between this one and the last one.

Let's try the next one. 1.3 Yeah, 1.3 here we go. Here We Go Again Changes are minor, maybe just some of the text I don't remember at this point what I did. All right, So let's skip one 1.5 and then let's look at that one now.

Okay, so 1.5 we start seeing some changes. You see I elongated those holes here. um I move this connector. That was a very important thing to do because now this board sits closer to the cell.

The cell Edge is right here and so it would. Um, it might short out right and so I moved that just from it used to be in line with this line right here with this Edge So I moved it in there and that gave me a little bit more room so that it wouldn't short out. And then here is where I change this connector from the very edge here I moved it in also to prevent some uh, obstruction when the metal box goes in there, right? Um, let me see. Other than that, I think that's it.

Let's look at the last one and here's number Six 1.6 Okay, so here's 1.6 and yeah, I think all these I think I I just ended up changing these right here, getting the the the correct size. um and this is the final one. This is the one that we're going to see right now. We're going to put it together so you know this is very simple.

Um, these are these are the traces, right? These are the layers of copper. so this is a top layer. It connects the two cells here and then two here, but then it connects those two to these two and then the same thing here. connects these four together, connects these four together, and then connects these two together.

And then these are the outlines of the aluminum bus parts that we're going to put. Uh, that we've that we've made, designed and you know, fabricated and then we're going to use them here. And so these lines right here are going to. It's just to help you.

Uh, show you where they're going to go if you happen to put these in the wrong place. Like if you put it here and then here, it would be a massive short when you put this one in here. So it's very important that you pay attention when you're assembling this and following these, uh, these markings right here when you're putting your battery together, right? So let's go to the bench. Here is our board.

Uh White is to distinguish all these big 148 amp, uh, 12vt ones and so all you have to do now is take your your eight cells like this and rearrange them. Right, Two negatives, two positives, two negatives, two positives, two negatives, two positives, two negatives, two positives and then you can put it in there. This is very, very simple and then it ends up being like this. All right.

So here we go. This is our Uh Bus bar here. The last thing to do is to put the D-shaped ones here right and those are going to go here and they're going to go here now. There are two types of nuts.

These ones have serr bottom edges right there and these ones are skinny. You're going to have to use these skinny ones on these because you need. There's just not enough room right? There's not enough threads sticking out here and we have to use these uh bus bars as quarter inch on these ones here. No problem.

These can be E/ inch because there's several Pathways to deliver the current and so they stay cool when this ones get hot because you have to squeeze everything through here right? So these ones right here. you'll use these big ones with the serrated end so that they don't come back. they don't come out that don't back out, You just put them in here here. Okay, so one of the things that you have to do, uh, if you want to use these like this, all you have to do is just, uh, put ring terminals in here and then you can use them like that, right? But if you want the terminal blocks, we have a link to those.

Uh, in the description of this video on the on the project, you know on the project page, there's going to be description. There's going to be links to all of these parts. Right. Where to get get these.

Where to buy these. Where to buy the cells. The connectors. All this stuff right.

and so also the terminals I don't have any terminals right now we ran out so that's why I can't show them to you? Uh, but you can put them in there and you can watch some of the older videos. the other ones that I've made, uh on the other versions of these batteries and you I show you how to put these together in here, right? So then the other thing that you have to do is just connect your balancer here and you know again I Explained on the other videos, you have to back out these little screws and open the holes and then stick them in there and then you can tighten them and then these, uh let's do that right now. you just connect that in there and then uh yeah, that's how you put your bouncers. It's very, very simple.

Now the other thing that we have for this right, You could use this as is if you want to mount we have options for mounting. These are called compression plates and you put them like this and they put some all thread in here and it compresses the batteries and then it has a flange that you can then use to screw these into your vehicle or into your project into your cabinet wherever you're putting these right. These are mostly used for car audio and so because they can push quite a bit of amps and car audio industry, they need this kind of amperage right? And so these are really great. Affordable way to put uh and secure your batteries into your project, right? But we also have a custom built battery uh, enclosure that's all metal and it kind of completes this whole thing.

Let me show you how that works. So this is the box. It comes as a kit. like this.

It comes all put together, assembled. What you have to do is you have to remove the top by removing all these screws and then you remove one of these sides you remove like this one right here, take off all the screws and then you take one of these ones too. It's just easier that way and what you do is you put your battery in there, slide it in here, and now you can put this again. Now you could put this, put the screws back on, and you put this one on.

And now that we have this now, you have to take these off and then put the Uh terminal blocks with the little Riser there's a/ quarter inch Riser that goes in here. The reason why we need that is to put this in here right? I Will make a more detailed video on how to put together this entire box. but this is just for this battery right here. and this is 148 amp, 12vt, 1200 amps for 10 seconds.

Very very powerful battery and this is for your car audio setup right? And so once you do this then it becomes like a finished plug-and playay battery that has a uh, a BMS thing or a balancer in here that you could see what it's doing. You can put this in your car all of a sudden you don't have access to all the stuff so that nothing can touch it and short out. all the only exposed things are going to be the main terminals here and then you can put all your cables in there. up to 20 high quality welding wire.

right? If you're using cheaper less uh, quality cable, then it might be like 1 or zero gauge or whatever to fit in those things, right? But there, there's several Uh inputs to put in here to put several cables. Uh, if you have several amps, then that's what you use those for in there, right? Um, there's also some text in here that will show you exactly how this goes. So anyways, this is an open source project sponsored by PCB Way. That's why PCB way.

It's right here on the Uh on the Pcbs. Uh, and you can buy all these uh at Jack 35.com and then you can go and you can even get them cheaper if you go to PCB Way.com Order the boards yourself right? and order all these parts yourself so that you don't have to pay me. You could just get them um, from the source. And now way.

You can make this battery in a most affordable way that you can, right? So again, this is a very professional, very high power battery. Can be used for anything that's 12 volts, but uh, it's mainly used for audio because it could do because that's who needs that much power at this low voltage right of 12 volts. Now you could build several of these and connect them in series. Uh, that definitely is a possibility.

You could do that. Um, Uh, I'm not going to stop anyone from doing that, but obviously I we do have other projects that will be able to do that like that one for there. for example, that's a 48 volt and then we will have a 36 volt. Uh, PCB Bus bar.

Uh, that? we're also going to release right? and so wait for that video if you need something other than 12 volts. Yeah, stay tuned cuz we have Pcbs for that. These batteries can be configured into any voltage pretty much that you need, right? Even all the way to 96 volts nominal which I am going to put with those boxes in there and we're going to test them on that car right there. We're going to even run a full car on all of these batteries right here.

These are very powerful and then very versatile. You can use them in all all kinds of project, all right. Thank you for watching this video! If Remember you could buy these already made ready to go or you can totally DIY They buy all the parts and then you assemble it and put it together right? Uh, either way, you're going to save a lot of money because this is a very high performance battery that will cost upwards of $1,000 but depending on how you buy it it, it will dictate how much you save. Definitely the cheapest way is to do the DIY version and you buy all the parts yourself yourself and then put it together right.

But if you're watching this video all the way to the end, that means that you're either interested and you're about to do this. Congratulations for joining the DIY movement! This is the best way to go. This is the best way to learn about new things right in this case, batteries and Battery building. And so if you have any questions, put it in the comments of this video and our whole Community we also have a Facebook Community Jus DIY power walls in which we talk about all these batteries and stuff.

There's a lot of people that are talking in there and so if you have a question you post it in there whether I answer it or sometimes other members of the community will answer it right. So again, thank you for watching. Thank you PCB way for sponsoring this video. We'll see you guys on the next one! Bye.