Bus bars and battery interconnects

I’ve been drilling a lot of holes in copper bars – these bars are what connects the banks of battery cells to form the whole battery. I think there were 198 holes drilled. It was enough holes that it made sense to fix my drill press. Once the drillpress was fixed it was super fast to zap all those holes.

I used the nissan battery pack connection strips as a template for hole alignment – which also meant that I had to exactly compress the pack back to it’s spacing before. It was easier than it sounds – torque on the compression rods holding the packs together increased slightly when the modules wouldn’t squeeze together anymore, so that was the signal to stop tightening.

 

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