Making an EV Battery Pack is Hard | 900hp Electric Escape Project

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  • Опубліковано 22 тра 2023
  • Use code AGINGWHEELS50 to get 50% off your first Factor box at bit.ly/3JBxZfN!
    Patreon: / agingwheels
    Merchandise: crowdmade.com/collections/agi...
    Tools and stuff:
    Laser Cutting: oshcut.com/
    Battery Modules: tinyurl.com/2bmjyn26
    Parallel Boards: tinyurl.com/4bsn7bb2
    Thermal Pad: amzn.to/3IyGYg8
    Cloth Insulative Tape: amzn.to/45t6Rb0
    Vise Bender: amzn.to/3orhZVn
    Weld-on Fittings: tinyurl.com/yc5yt6wk
    Many materials came from www.mcmaster.com/
  • Авто та транспорт

КОМЕНТАРІ • 1,5 тис.

  • @agingwheels
    @agingwheels  Рік тому +158

    Use code AGINGWHEELS50 to get 50% off your first Factor box at bit.ly/3JBxZfN!

    • @Firestarg
      @Firestarg Рік тому +3

      Hey as long as your ok.. you take as much time as you need to do it like you want! Thanks for the video

    • @man_eating_monkey
      @man_eating_monkey Рік тому +3

      What’s the coupon code for the turkey?

    • @micrashed
      @micrashed Рік тому +3

      It is coming closer to fruition - I cant wait to see it run.

    • @andrewpopoff3453
      @andrewpopoff3453 Рік тому +1

      I like the thing you're doing, if you would like some help on future projects. Like modifying those battery boards with the right angle connectors, I have soldering and desoldering equipment to make that job easy. Let me know and keep having fun

    • @THISLOVETHISHATE99
      @THISLOVETHISHATE99 Рік тому +2

      did i just witness u place that top cooling plate on without removing the protective film on that thermal pad 20:23

  • @simplegreen6596
    @simplegreen6596 Рік тому +2969

    As an IT guy, and a car guy. I gotta say man. Dont change your delivery style. It does NOT go unnoticed the amount of time and work you put into the projects as well as the editing. Dont fall into the UA-cam trap of putting out a video a week. Keep on the pace you have, its working great. Great work

    • @nicki8731
      @nicki8731 Рік тому +66

      I'm very confident he's in debt after this. He's probably barely staying afloat, even with the sponsor, 300k subs, patreon, and other sources of money.

    • @danielseelye6005
      @danielseelye6005 Рік тому +51

      It might work great but if he's basing his primary income from UA-cam, he sort of has to "Chase the Algorithm." So long as his patrons can subsidize him to not be dependent on AdSense, then it can work to go at his pace.

    • @nicki8731
      @nicki8731 Рік тому +26

      @@danielseelye6005 yeah, you said it better. The reason people upload once a week is to pay their rent and grow their channel.

    • @dancardin2087
      @dancardin2087 Рік тому +14

      @@nicki8731 Based on other youtubers who make their income amounts known, I'm not so sure? Shop Nation, for example makes ~100k/yr between adsense and sponsors with fewer subscribers, releasing bi-weekly. Plus patreon, plus Under Dunn. idk. certainly this is expensive, but for all we know, this is all just a hobby on top of non-youtube income?

    • @jonathonboerema8886
      @jonathonboerema8886 Рік тому +9

      Hey me too, I think we are his target audience. I agree with you, don't change keep it genuine please.

  • @MaltaLumpie
    @MaltaLumpie Рік тому +1371

    The presume joke is just top tier gold

    • @pkonneker
      @pkonneker Рік тому +52

      That deadpan delivery is money

    • @Kyomara1337
      @Kyomara1337 Рік тому +16

      yea, that one caught me totally off guard

    • @veanny2005
      @veanny2005 Рік тому +4

      How did you commented 1 day ago when the video got published 4 hours ago ????

    • @MaltaLumpie
      @MaltaLumpie Рік тому +14

      @@veanny2005 Patreon :) Link under the vid

    • @davedave6514
      @davedave6514 Рік тому

      Laughed so hard

  • @SimuLord
    @SimuLord Рік тому +359

    Those multiple drill-hole montages never get old. Great piece of editing.

  • @doppelhub
    @doppelhub Рік тому +139

    Howdy from a fellow EV battery designer. Unfortunately, I bring bad news: the paralleled cell voltage monitoring system you're using is dangerous to use. The connecting wires between each cell must be able to source considerably more current than those small wires can handle. Imagine the following scenario: one cell in one module gets weak. You then pull 100 amps through the pack. Since the weak cell is connected with the OEM bus bars, its voltage is going to drop considerably. This causes two problems: 1): A several volt drop occurs across the BMS wire (from the good cells to the bad cell), which can easily burn the wire; and 2) Since the BMS is measuring the combined voltage of four modules, it won't detect this failing cell (the good cells will mask it); and 3) since you aren't detecting weak cells, the remaining good cells in parallel are going to get worked harder, causing them to degrade faster (a positive feedback loop). Obviously you didn't design this system (you mentioned you purchased it from someone else), but I strongly encourage you to either A): Add high current busbars between each paralleled cell, so that it can handle the peak pack current (this is infeasible in your design), or B): Get a separate cell voltage monitor for each module (4x more parts).

    • @doppelhub
      @doppelhub Рік тому +17

      Note that some people try a third option - limiting current by adding series resistors (e.g. on those PCBs) - but that only solves item #1 (in my previous post). Items #2 and #3 remain an issue.

    • @squ1dd13
      @squ1dd13 Рік тому +14

      i know nothing about EV battery design, but have my comment for visibility. hopefully he sees this.

    • @SianaGearz
      @SianaGearz Рік тому +7

      The boards are effectively internally fused so... i think you can expect a particularly bad cell subgroup with high compensation current to just fall off the cell voltage monitoring and compensation as the fuse triggers and then worse things can happen, as bad cells can become prone to be reverse biased by forced series current, which is a cause for super degradation of already degraded cells. It crossed my mind when watching, but ultimately i don't have experience in large series-parallel banks.

    • @melovescotch
      @melovescotch Рік тому +10

      Another EV battery designer here, yep there is an danger here, as you pointed it out. Also I worry about High voltage isolation with the cooling plates/thermal pad he's using, hope their rated as the same that was specd in the original pack.

    • @johnhan8173
      @johnhan8173 Рік тому +9

      Was hoping I misunderstood the design while watching but as I understand it this is really a significant issue :( Having built an EV battery and having seen some crazy battery fires I really hope this gets addressed safely!

  • @aidanh4550
    @aidanh4550 Рік тому +956

    This project legitimately can land you a job designing EVs. Your dedication is incredible

    • @vailpcs4040
      @vailpcs4040 Рік тому +93

      We are watching a guy go through the entire technical evolution of an EV. It's amazing.

    • @Blasterxp
      @Blasterxp Рік тому +11

      I would drive one with proud!

    • @beardsntools
      @beardsntools Рік тому +17

      Everything about this is incredible.. except for the EVs themselves.. they suck

    • @Apokathelosis
      @Apokathelosis Рік тому +29

      So that he could no longer be his own boss, but work for the profit of corporate stakeholders. Sounds like great deal.

    • @AB0BA_69
      @AB0BA_69 Рік тому +7

      Pretty sure you need an actual degree to land a job like that 😂😂😂

  • @BerthaTurtleOfficial
    @BerthaTurtleOfficial Рік тому +183

    Thanks for showing your struggles. Sometimes progress on my projects suffer because of the fear of getting something expensive wrong. It's reassuring seeing you persevere and even if after a slight break, move forward and find success. Thanks for sharing your passions!

    • @jd_99
      @jd_99 Рік тому

      It might help though if his tools didn't seem to be made of finest chineseum

  • @_topikk_
    @_topikk_ Рік тому +99

    I'm torn between dying to see this project finished and never wanting this build series to end.

    • @TravisL.Desmadreson
      @TravisL.Desmadreson Рік тому

      You can say that again.

    • @aidenpommee766
      @aidenpommee766 Рік тому +11

      You can probably have both seeing the end of this series then the bus series would start up again

    • @kindadumbkindastrong4429
      @kindadumbkindastrong4429 Рік тому +4

      ​@@aidenpommee766 was just gonna say the sooner this ends the sooner the bus starts

  • @rickjames7391
    @rickjames7391 Рік тому +183

    I really appreciate that you remind us how long it all takes without making us feel that pain.

    • @SaraMorgan-ym6ue
      @SaraMorgan-ym6ue 5 місяців тому

      he's finding out why everyone does not make there own ev cause it's hard plain and simple

  • @kyledexter485
    @kyledexter485 Рік тому +118

    Always a great day when a new Aging Wheels video drops!

  • @DaBomb31290
    @DaBomb31290 Рік тому +246

    Your level of commitment and patience is insane.

    • @rogersmith7396
      @rogersmith7396 Рік тому +2

      Thats what his wife said at the divorce hearing.

  • @sebastianeckert1947
    @sebastianeckert1947 5 місяців тому +7

    Did you good folks notice the compassion and relief when he caught this baby bird? This guy has a big heart for sure

  • @mundanestuff
    @mundanestuff Рік тому +39

    I'm currently paralyzed to inactivity on three car projects, so keep doing what you're doing! It's inspiring me to get my ass off the couch and get some work done, learn new skills, break some tools. Edit: signed up on your patreon link! Worth every penny.

    • @rogersmith7396
      @rogersmith7396 Рік тому +2

      The trick is to break out of logical progression and do what ever you feel like doing. I am currently carpeting the trunk of my 70 Cadillac. Instead of all the more important things. Its low drag. Low effort, low sweat.

    • @isaakwelch3451
      @isaakwelch3451 Рік тому +3

      For me, the more I think about my projects the more I get paralyzed. If you force yourself to get out there and do something, even if it's minor, you'll get the big things done too. You can do it!

    • @XH1927
      @XH1927 Рік тому +1

      Set a Tesla or Hyundai on fire. It's not only a project, it's a public service.

  • @therealpanse
    @therealpanse Рік тому +128

    not even 4 hours ago I was at work thinking to myself "haven't seen something from this channel for a while. Even this old tony has a new video. I hope he didn't burn down the shop with those batteries..."

    • @anefyon
      @anefyon Рік тому +8

      Same I was binging old aging wheels videos yesterday night hoping for an update on the escape lol

    • @haydenc2742
      @haydenc2742 Рік тому

      IKR!!!!!

  • @NekiCat
    @NekiCat Рік тому +84

    The number one killer for batteries is heat. So having cooling, even if not strictly necessary, is very good to have!

  • @derekchristenson5711
    @derekchristenson5711 11 місяців тому +29

    The fact that you face all of these difficulties and setbacks but keep going, making something interesting and cool, is really something. 🙂

  • @yestrep333
    @yestrep333 11 місяців тому +18

    Awesome Build! I was a battery thermal management engineer at my previous company and I specialized in the design and manufacturing of cold plates for several OEM battery packs (Ford, Stellantis, Rivian, etc). I think your approach is well thought out, but be very careful of leaks. Your joints are not brazed or welded so they may fail after being pressure and thermally cycled over time (Even though they do not leak at operating pressure). Luckily your flow path is very non-restrictive so you will have a low system pressure drop if you run your cold plates in parrallel (1 Shared inlet for all plates, 1 shared outlets for all plates). If you run the cooling plates in series, you will definitely risk a higher pressure drop causing bursting plates and you'll also see a much worse cooling performance on your last module in the linear chain (Linear meaning that the outlet of one cold plate feeds into the inlet of the next and so on). Thermal adhesive padding was an excellent idea and
    A better DIY method for cold plates is to use "Aluminum flat extruded microchannel tubing". These can be bought relatively cheaply from Alibaba or a local supplier. You would need to make a custom manifold for each end of the tube, but the tube naturally wont leak or burst from the coolant pressure so it is much safer and more reliable. It also naturally has a well distributed flow path so cooling is rather even across each individual module and across all modules as a complete system. The manifold can be welded or brazed to the pipe to form a leak free joint that will hold up over time.
    For your specific batteries and power output, you can expect to use a ~16gpm pump for the entire system. a higher output pump will be better, but definitely louder

  • @andrerenault
    @andrerenault Рік тому +57

    7:13 I felt that “I’m going to take the rest of the day off” in my soul. R&D can be brutal

  • @jimcabezola3051
    @jimcabezola3051 Рік тому +223

    You solved SO many engineering problems here. For their Leaf car, in contrast, Nissan DIDN'T solve all the issues that you did; they left their modules air-cooled. I believe your solutions will bring you long-lasting battery capacity. You did an outstanding job making these things and an outstanding job explaining what you did. This is why we all keep coming back for your videos. Brilliant!

    • @Tomazack
      @Tomazack Рік тому +20

      Anyone who's tried to quick charge a Leaf (both first and second gen) will understand after the second and third quick charge why active cooling is important.

    • @JoshuaRes
      @JoshuaRes Рік тому +1

      @@Tomazack truth.

    • @mjc0961
      @mjc0961 Рік тому +6

      @@Tomazack I don't even need to try and quick charge a Leaf to know why active cooling is important. I just need to look at the climate. The Nissan Leaf would be a PERFECT car for my driving needs, EXCEPT I have winter and having the battery just stay at below freezing temperatures isn't going to cut it.
      Okay to technically that's active heating, but it's the same system that does the active cooling.

    • @mjc0961
      @mjc0961 Рік тому +4

      @@dizzy2020 Surely Nissan can do a version of the Leaf that has active heating & cooling and isn't that much more expensive, though. That's a car that would yes cost more but also suddenly work "well enough" for a lot more people meaning much larger potential sales.
      I don't need fast charging, but I do need the battery to warm itself during winter.

    • @Sabrinahuskydog
      @Sabrinahuskydog Рік тому +3

      @@dizzy2020 It's an automotive vehicle sold in the USA. They should design it to withstand any and all possible environments anywhere in the USA from the severe sub-freezing winter temps up north to the literal desert of Nevada. Just because they only sold it in one region does not mean it won't change owners and be taken to a different region.

  • @ryanseidel7436
    @ryanseidel7436 Рік тому +55

    I think you've perfectly captured how hard it is to design something from scratch. No manual, just a bunch of trial and error. Great job, great video

  • @brunobellomunhoz
    @brunobellomunhoz Рік тому +2

    I love how I can only understand half of what he's saying, but I still love to watch.

  • @PureVulcan
    @PureVulcan Рік тому +205

    Definitely have the right idea towards the epoxy for the cooling plates but surface prep for gluing is super important especially for aluminum. To do it well, I'd recommend sanding the surface with a midgrade sand paper then cleaning with isopropyl alcohol and letting it evaporate before applying the epoxy. The idea is you want to remove surface contaminates and give the glue more surface area to hold onto with the surface roughness.

    • @rarbiart
      @rarbiart Рік тому +37

      i just hope that preparation was done off camera. otherwise we will see a revisit after the first bumpy roads.

    • @KriLL325783
      @KriLL325783 Рік тому +30

      Yeah honestly the current design gives me no confidence at all, hopefully he did more prep work and, I don't think leak testing by submerging in almost no water is a good approach, I'd have run water through with some pressure and flow, it and if possible varied the temperature of the water to see how the glue handles thermal expansion, personally I'd have used a lot of counter-sunk screws along the whole edge going into threaded holes on the other side with a flexible o-ring in a channel around the edge

    • @alxgu198
      @alxgu198 Рік тому +5

      I’d have just used aluminium instead 🤪

    • @PureVulcan
      @PureVulcan Рік тому +2

      @@KriLL325783 yeah I agree, and that would work too, but I've had good experiences with epoxying aluminum even in demanding structural applications to other materials and itself but surface prep is key. I've run tests on good prep vs washed with water vs no prep and the difference is significant in terms of the bond strength. Also I don't imagine that with coolant flowing though it that the thermal expansion will really be an issue but I don't know what these batteries are rated for.

    • @onix331
      @onix331 Рік тому +9

      Yeah i don't think that epoxy job is gonna hold up for long, but thumbs are pressed

  • @kahnwolfe9548
    @kahnwolfe9548 Рік тому +14

    Just love that whole "It's clear so if something goes wrong I can see inside to see if there is smoke or something." and was just waiting for a *foreshadowing* prompt to pop up.

  • @rockoyouthman
    @rockoyouthman Рік тому +2

    The factor commercial was seriously the BEST humor I’ve seen on UA-cam in ages. I never listen to adds. I listened to this one! Hahahahaha. Awesome. Yup. I’m sold and will try Factor.

  • @nicholas5623
    @nicholas5623 Рік тому +21

    your ability to just tackle any sort of project is very inspiring. i love the way u film edit and talk in the videos. dont fall into the pitfalls of youtube and think we need a video a week. quality over quantity

  • @gannas42
    @gannas42 Рік тому +35

    I really appreciate that you keep it real and f up at least as much as the common person does. If you edit out some of it you should consider a bloopers supercut video. 😂

  • @benjaminchung991
    @benjaminchung991 Рік тому +37

    Those EVWest adapters/harness boards can be made extremely easily and cheaply. Just superficially, I think that the materials cost per unit is about $5 (mostly in the big honking connector) and then you can get the boards made for $20/20.

    • @lasskinn474
      @lasskinn474 Рік тому +2

      the evwest boards cost 44 for one. so 20 bucks to make one would kinda fit in that.
      it's not thousands he could save on them though, more like half a grand.

    • @Mackze
      @Mackze Рік тому +4

      Right? They're overcharging big time, its ridiculous actually

    • @benjaminchung991
      @benjaminchung991 Рік тому +1

      @@lasskinn474 To be clear, I think that material cost would be about $6/board ($5 for the connector, $1 for the PCB).

    • @ticso24
      @ticso24 7 місяців тому

      Maybe I got the setup wrong, but to me those boards look like a fire hazard.
      The packs have multiple cells and are in parallel.
      The PCBs now connect the individual cells in parallel with thin wires.
      There are fuses, which protects the wires, but those fuses are the issue.
      With only one BMS and those paralleled cells the BMS won’t notice when a fuse is blown, but a given cell is now unmonitored and can overcharge.
      Furthermore it absolutely will over- or undercharge, since a bad cell is likely the reason why the fuse was blown in the first place.
      If the individual cells are not paralleled with big bus bars they have to be monitored separately.

  • @hyahmuleart7144
    @hyahmuleart7144 Рік тому +28

    This is just incredible. I’m so glad that I found your channel and I’m looking forward to going through your back catalog on this ridiculous project.
    The breakdown of the different types of automotive batteries sold me on your channel. You just happen to go to the perfect level of depth for me.

  • @IstasPumaNevada
    @IstasPumaNevada Рік тому +3

    Of all the styles of "showing progress of personal projects" I've seen, I like your style of real-time-cut-into-rapidfire-snippets style of timelapse the best.

  • @tomhsia4354
    @tomhsia4354 Рік тому +34

    I hope you make the deadline.
    Don't rush it, though, wouldn't want a battery fire on your hands.

    • @agingwheels
      @agingwheels  Рік тому +48

      Holley High Voltage hasn't even been announced this year, so I don't really know when the deadline is! But, like you said, I ain't rushing nothin'

    • @Blue__244
      @Blue__244 Рік тому +1

      @@agingwheels why didnt you weld the coolant plates?

    • @rogersmith7396
      @rogersmith7396 Рік тому

      @@Blue__244 That will probably be necessary. Not in house.

  • @mxadema
    @mxadema Рік тому +54

    I really appreciate the effort put into this EV conversion. Why do easy all tesla parts, when you can pick one part and painful build everything around one of it feature.
    It impressive, i like it

    • @michaelmastropietro8292
      @michaelmastropietro8292 Рік тому

      I think some of the greatest vehicles followed this exact principle.

    • @danielseelye6005
      @danielseelye6005 Рік тому +2

      The other thing to think about is if he used Tesla stuff, there's a good chance he would void the warranties of the equipment just trying to fix stuff. This way, he knows what's in there because he put it in there.
      Just like Jared Pink: He _Is_ the Warranty.

    • @rogersmith7396
      @rogersmith7396 Рік тому +1

      And not end up in bankruptcy court.

  • @itsmephil2255
    @itsmephil2255 Рік тому +2

    Well Robert, you are either a certified genius or an authentic wacko!!!!
    Awesome stuff man

  • @BKepple85
    @BKepple85 10 місяців тому +4

    I felt every moment of stress and difficulty. This is real. For those of you who haven't created something from scratch in their lives... this is exactly how it is. It's frustrating but highly rewarding when you're done.

  • @bami2
    @bami2 Рік тому +17

    I love the use of the polycarb, looks so much better than just an opaque box.

  • @vaderman212
    @vaderman212 Рік тому +10

    Sneaky Under Dunn segment lol

  • @MrCrousenn
    @MrCrousenn Рік тому +24

    Been watching you for some years now, from all "YT mechanics" you got THE BEST quality of production. Like, when you see the section with fast cuts of welding/drilling/tightening etc. I just imagine how long it takes, positioning the camera everytime differently and then cutting it into sections. This is really getting the viewer deep into the process without boring to death with long sections were nothing happens. Amazing job. Give this man more subs and views, this project alone makes it worth, not to mention all your other stuff that's awesome

    • @XH1927
      @XH1927 Рік тому

      WatchWesWork, ViceGripGarage, Diesel Creek, countless other people who aren't propagandists just aren't on your radar, huh? Troglodyte.

  • @scoutsapp5624
    @scoutsapp5624 Рік тому +23

    I love how this channel just keeps getting more insane in a good way.

  • @squ1dd13
    @squ1dd13 Рік тому +18

    and here i was thinking your presentation style couldn’t get any better… you’re doing a fantastic job. i love the delivery, commentary and editing. it’s brilliant. ❤

  • @theallsopteam7943
    @theallsopteam7943 Рік тому +46

    Amazingly informative and massively funny as always, sometimes wish id found your channel 5yrs from now, then I could just binge it all!!

  • @killingtimeitself
    @killingtimeitself Рік тому +2

    i swear nearly every video you pull up with something new that you've learned or have started learning, honestly im impressed at the rate you manage to deal with new stuff, even I can't do it that well and learning new things is one of my favorite things.

  • @peterl9097
    @peterl9097 Рік тому +4

    Man I've been watching you for the last 7 years... gotta say, you've improved immensely from rebuilding a carburetor to a full blown EV car!! that's cool as hell and you should be proud of the work you've done up to this point!!!

  • @jtr159
    @jtr159 Рік тому +9

    Dude I respect the enthusiasm and positivity so much. I have the same attitude of "do it now and figure the rest out later" and 80% of the time it does mean undoing half and starting all over...good to see a big-time youtuber doing the same.

  • @Ingineerix
    @Ingineerix Рік тому +7

    @Robert, I seriously doubt epoxy will work on aluminum for a hermetic seal. Even if you get one to seal temporarily, (pun?) the temco (temperature expansion coefficient) of aluminum and it's propensity to have have a tough oxide coating on all surfaces exposed to air means the epoxy joint will eventually fail. You'd need to weld the perimeter to solve this.

  • @JeremyMakesThings
    @JeremyMakesThings Рік тому +4

    Sometimes I feel like it’s hard to capture the magnitude of work, struggle, and frustration of a project like this that feels likes it’s constantly fighting you. But you did a beautiful job expressing it in this video, and the battery box looks great too. Keep up the good work, you’ll get it done!

  • @chuckbrown617
    @chuckbrown617 Рік тому +1

    I have to say that this is the only YT channel where I don't skip over the ads. You make them as entertaining as the rest of the video.

  • @gabrielscake9916
    @gabrielscake9916 Рік тому +4

    Absolutely loving this series. One of the rare occasions where I’ll drop everything I’m doing to watch the most recent episode

  • @mushroom89
    @mushroom89 Рік тому +12

    11:50 is there going to be a problem with airflow through the radiator if there's a big solid sheet of polycarbonate blocking it on the other end?

  • @Naademai
    @Naademai 11 місяців тому

    I really hope we still get videos of the rest of the battery box construction because I do really love your working montages, I just love your videos in general, I probably rewatch a dozen videos a week

  • @dougandrews6767
    @dougandrews6767 Рік тому

    Jesus Murphy! You are a true mad genius. Your attention to detail in building the batteries & filming puts other UA-cam channels to shame.

  • @mceajc
    @mceajc Рік тому +18

    This represents SO MUCH WORK! Truly impressive. The day of the four-wheel skids approacheth.
    Also, additional thumbs ups's's's: Resume/presume and Mahogany.

  • @thetastefultoastie6077
    @thetastefultoastie6077 Рік тому +3

    $1050 for those trivial PCBs is absolute insanity!
    It would take about 10mins to design in KiCAD and export to JLCPCB who would make it for a few bucks.
    The connectors would be, by far, the majority of the cost.
    You know what? Next time you need some, hit me up; I'll sell them to you for half price 😁

  • @danam2584
    @danam2584 Рік тому +6

    You are the man!! You put an amazing amount of work into your projects and videos. Well done Robert!

  • @Kejogre
    @Kejogre Рік тому

    Dude, your engineering genius is Apollo 13, 1970 "improvise and and make it work when no one has ever conceived of this before" level amazing. And you made it pretty.

  • @toadbroz30
    @toadbroz30 Рік тому +4

    Cant wait for next months update! Seriously, this is such a great project. Don't rush as we all see the hard work going in.

  • @TomWallior
    @TomWallior Рік тому +5

    This battery box looks stunning! And I actually enjoyed every second of this video, even though I suck at electronics.

  • @chrisadams628
    @chrisadams628 Рік тому +1

    If you have trouble with the cooling plates down the road, have someone TIG weld them all the way around the outside edge to seal them up.

  • @francistheodorecatte
    @francistheodorecatte Рік тому +14

    ...it might be better in the future to use a glue like 3M window weld to hold the cooling plates together, and rely on the clamping pressure of the threaded rods to keep them pulled tight.

    • @jimurrata6785
      @jimurrata6785 Рік тому +1

      Yes. And a vacuum bag would be an ideal clamp to hold the plates together until cured.

    • @rogersmith7396
      @rogersmith7396 Рік тому

      How about that PL stuff they build pickup trucks with?

    • @jimurrata6785
      @jimurrata6785 Рік тому

      @@rogersmith7396 I'm not sure the specific product, but I would say 'no good' on aluminum, under pressure, carrying liquid and with vibration.
      That big aluminum sheet has to grow a lot when it gets hot.

    • @rogersmith7396
      @rogersmith7396 Рік тому

      @@jimurrata6785 I have tried to do similar things with hot liquid under pressure. Its no go.

    • @jimurrata6785
      @jimurrata6785 Рік тому

      @@rogersmith7396 What product are you talking about, specifically?
      Henkel/Loctite makes PL. It's just their line of construction adhesives. (but I've never seen it on a pickup truck)
      They have plenty of bonding epoxies for aluminum in Aerospace and Automotive lines that would hold up just fine.
      Id be a little iffy about G10 (and I use it a lot!) but I don't know how hot the plate gets. Gougeon Brothers has a very good technical department that is able to answer questions about their products suitability for oddball projects. Robert might have contacted them, but I didn't see him sanding the epoxy into the surface like they would recommend....

  • @mrq1
    @mrq1 Рік тому +7

    Impressed by the amount of work you've put into this. Also your editing style is incredible.!

  • @elitecpudoc329
    @elitecpudoc329 Рік тому

    "Is this overcomplicated? No, its just complicated" is such a great quote. but within your build everything has a purpose and there is a purpose for everything.

  • @stanleywatson2559
    @stanleywatson2559 Рік тому

    Dude you should make a channel for the fowl. Your face when bird almost fell off the box was priceless.

  • @docnele
    @docnele Рік тому +5

    Please, pay attention to this detail about coolant (it goes for ethylene glycol mixture, but can be true for some others). Water has a bigger "drop" then coolant, which means your radiator can be watertight, but may not be coolant-tight. I know you tested it under pressure to be sure, but test it with coolant as well. Maybe to go with waterless?

    • @JimnyVR5
      @JimnyVR5 Рік тому +7

      He tested with air tho... airtight is for sure watertight

    • @docnele
      @docnele Рік тому

      @@JimnyVR5 True, I guess I am tired from work :P

  • @drumbrakes
    @drumbrakes Рік тому +6

    Is that Battery box getting its own contactors & MSD?
    With 4 battery boxes to join up & two motors, that's a lot of scary orange ropes going in a lot of different directions and they take up a fair bit of room. Good to plan where they go and where the breaks are positioned in advance.

    • @agingwheels
      @agingwheels  Рік тому +7

      I hadn't considered separate contactors for each box, but it's not a bad idea.

    • @GrayRaceCat
      @GrayRaceCat Рік тому +3

      @@agingwheels Unfortunately, US federal code requires no voltage above 60 volts be present 5 seconds after a collision. This applies to home built as well as production EVs. For the safety of you and first responders. This means two contactors, a service plug, and a fuse for each box. I will look up the source and post a link as soon as I find it.

    • @drumbrakes
      @drumbrakes Рік тому +1

      ​Just be careful with how you wire the cell taps to the BMS. You shouldn't have a disconnect, fuse or contactor within a single grouping to the BMS, as you would get high voltages across the taps as they open/close and that lets the smoke out of the BMS. Replacement Smoke is available, but very hard to install.
      I think I like the idea of those parallel BMS PCBs, but do you need to balance all the cells between the parallel modules before you connect them? You're getting modules from multiple vehicles which will each have different SoC and SoH, could be a nightmare...

    • @drumbrakes
      @drumbrakes Рік тому +1

      @@GrayRaceCat Interesting, that would then need some sort of impact sensor included in the interlock?
      The modules are 57.6v each, so would that require a break between the two banks in the 8 module boxes (4p32s 115v) or is it enough to have the outputs of the box isolated?
      Contactors rated for those current levels will not be cheap.

    • @GrayRaceCat
      @GrayRaceCat Рік тому +2

      @@drumbrakes On later cars folks are taking advantage of the Airbag System or using the inertial fuel pump cut off to cut 12vdc power to the contactors. On early cars you would have to get creative.
      If I understand the standard correctly, isolating the HV to the inside of the battery boxes with contactors is sufficient, the fuse is extra insurance in case a contactor is 'welded' closed or the box has been punctured.

  • @KentHenry8
    @KentHenry8 Рік тому

    That clear battery box is truly spectacular.

  • @MrSolvalou
    @MrSolvalou Рік тому

    Each of your videos, especially the Escape project, are amazing. Do not feel like you need to rush the videos out, they're totally worth the wait!

  • @wild3miri
    @wild3miri Рік тому +8

    the clear battery box looks epic with the mahogany. you should add LED strips inside the engine bay around the box to light it up.

  • @ZGryphon
    @ZGryphon Рік тому +4

    This would all be so much simpler in the timeline where all you gotta do is throw a General Atomics Mk XVII mini-reactor in there and plumb up the liquid sodium.

    • @rogersmith7396
      @rogersmith7396 Рік тому

      Na will explode on contact with air. And its what, a few thousand degrees. Florida Man would approve. What could go wrong?

  • @gamboodle
    @gamboodle Рік тому

    the box is beautiful! love that you keep all the details about what youre doing in the vids, its all very facinating so it really adds a lot!

  • @jeremiahjohnson3018
    @jeremiahjohnson3018 Рік тому

    Your editing is so on point, I can hardly contain myself.

  • @LightTheUnicorn
    @LightTheUnicorn Рік тому +3

    Your work and dedication on this project is nothing short of incredible! It's absolutely wonderful to watch you overcome issue after issue.

  • @fgbhrl4907
    @fgbhrl4907 Рік тому +3

    fifteen... hundred dollars!? For $20 of PCBs? That is insane. I will literally design those for you for fun.

  • @cakeisalie
    @cakeisalie Рік тому

    I love how you are just winging it professionaly

  • @tylerw4593
    @tylerw4593 Рік тому

    10:36 The resume-presume bit just earned you a new subscriber

  • @salzar4431
    @salzar4431 Рік тому +3

    I take my hat off to you, this is an epic project. I’m loving it.

  • @leahheffernan4644
    @leahheffernan4644 Рік тому +3

    Drag race unsuspecting people after its built!

  • @felixmakesart
    @felixmakesart Рік тому

    I comment something like this almost every video but his humour gets me every time. Never stop being you, Robert

  • @TheChoirDirector
    @TheChoirDirector Рік тому

    Thank you for continuing to share!!!

  • @wcvp
    @wcvp Рік тому +11

    Man I'm wanting to make my old F350 a hybrid, and it looks like that is going to be more work than I was hoping for.
    For those battery breakout boards, what is included with that? If it's just the board and 4 connectors it would probably be cheaper (and faster) for you to just have some PCB's made and you populate them yourself for the other battery boxes. Plus you wouldn't have to string 4 of them together. I could probably do it for you real quick if you aren't familiar with that.

    • @agingwheels
      @agingwheels  Рік тому +15

      It's the boards and the wiring harnesses. I probably could've done it myself, but I didn't want to design yet another thing. Plus, there are worse places to spend money than EVWest

    • @wcvp
      @wcvp Рік тому +6

      @@agingwheels Makes sense, doing those harnesses yourself would suuuuuuuuuck lol
      And it's probably where a lot of that cost comes from

    • @lasskinn474
      @lasskinn474 Рік тому +1

      @@wcvp i think the price is for them for all of the packs not just this one

  • @aftbit
    @aftbit Рік тому +4

    Wow $1000 for those 4 paralleling boards? Are those grey connectors made of platinum or something? Also you definitely need to secure those together. The inter-board connectors are not going to do well in vibration.

  • @LunaWuna
    @LunaWuna Рік тому

    This channel has the only sponsor reads I dont skip

  • @NoNonsense316
    @NoNonsense316 Рік тому

    This is an incredible project, and yet you make these videos fun to watch and easy to follow. Great work; please keep it coming.

  • @FFcossag
    @FFcossag Рік тому +10

    PLEASE READ THIS, AGING WHEELS! You've built a very, very dangerous battery here, because you DO NOT have any way to isolate the parallel modules from each other!! If you suffer any single cell failure, this battery WILL NOT BE PROTECTED BY YOUR BMS! In the case of one cell going short, all that will happen is that the fuse on the breakout board will blow, the bad cell will fall out of monitoring, and most likely suffer a THERMAL RUNAWAY POWERED BY THE OTHER PARALLEL MODULES, that your BMS WILL NOT be able to shut down!
    Whenever you parallel modules with multiple series cells inside, you need to use a separate contactor on each parallel string. That's why you never see this configuration of cells in production EVs.

    • @FFcossag
      @FFcossag Рік тому +7

      This problem arises because if a cell goes short (or starts leaking a lot of current), the nominal voltage of that module will drop by one cell and it will essentially turn into a 7-series module with a resistor in series. Since that 7-series module is hard-wired in parallel with several 8-series modules, uncontrolled current will flow from the good modules into the bad one. The failed cell will produce uncontrolled heat, and the non-failed cells might see an overvoltage condition of up to 4,8 V/cell if the failure occurs at a high state of charge. The BMS might notice that the temperature is rising, or that the cell voltages are too high, but it will be unable to terminate the connection between the modules since they're literally bolted together.
      I repeat: Your BMS **WILL NOT PROTECT YOU FROM A THERMAL RUNAWAY IN YOUR CURRENT BATTERY CONFIGURATION!**
      I just want you to be aware of this.

    • @scottdotjazzman
      @scottdotjazzman Рік тому +2

      Agreed. All cells must be capable of being isolated individually for the battery to be safe, and lithium ion cells should never be monitored as a group.

  • @JCWren
    @JCWren Рік тому +3

    I don't like those 4 interconnect boards plugged together. That seems like a very real failure point. It would actually be fairly easy to lay out a custom PCB to handle that and for 1/10 the price of EV West is charging (assuming the connectors themselves aren't like $100 each).

    • @moconnell663
      @moconnell663 Рік тому +1

      The connectors are $5, JAE Electronics MX84B028NF1

  • @kliether33
    @kliether33 Рік тому

    awesome job! love the woodwork thrown into the electrical project

  • @MrBuyerman
    @MrBuyerman Рік тому +2

    This box is a minor work of art. Nicely done

  • @KevwePatani
    @KevwePatani Рік тому +3

    Every other week I'd think to myself, "Robert sure is taking his time with those battery boxes"
    Now 2 months has passed and you've only made one😂

  • @sasanmottaghipour876
    @sasanmottaghipour876 Рік тому +1

    I am really looking forward to the finished enginebay piece! and all the lovely cablemanagement

  • @leaving_marks
    @leaving_marks Рік тому +1

    This project is very exciting, can't wait to see the final result!

  • @metatechhd
    @metatechhd Рік тому +9

    💻🚗🙌 As someone who shares your passion for both IT and cars, I have to commend you on your delivery style. It's evident that you put a tremendous amount of time and effort into your projects and editing. I appreciate that you prioritize quality over quantity and resist the pressure to churn out videos on a weekly basis. Keep up the fantastic work, as it's clearly paying off. Your dedication shines through, and your content is top-notch. Great job! 👏👍🔥

  • @sophie82807
    @sophie82807 Рік тому +57

    I'm no longer waiting for the GRANT LOAN because I acquire $29,600 every 10 days recently.

    • @sophie82807
      @sophie82807 Рік тому

      After watching so many UA-cam tutorial videos about trading I was still making looses until Mrs Jenna started managing my investment's now I make $50,567 weekly. God bless Mrs Jenna she been a blessing to my family.

    • @Connor56212
      @Connor56212 Рік тому

      She helped me recover what I lost trying to trade my self

    • @Bellatrix416
      @Bellatrix416 Рік тому

      Wow I'm just shock someone mentioned expert Mrs Jenna, I thought I'm the only one trading with her,,

    • @Vasilisa787
      @Vasilisa787 Рік тому

      She's really amazing with her skills. She changed my 0.5btc to 2.1btc

    • @Eddie576
      @Eddie576 Рік тому

      I think I'm blessed because if not I wouldn't have met someone who is as spectacular as expert Mrs Jenna. I think that she is the best broker I ever seen

  • @neildrd
    @neildrd 11 місяців тому

    A++ for editing and writing !!

  • @arthodart4712
    @arthodart4712 Рік тому

    Its been so awesome to watch your progress on this project!

  • @kyleeverly9243
    @kyleeverly9243 Рік тому

    I take this both as an inspiration and a warning in my own EV project. Your dedication is impressive. Thanks for the updatea

  • @nexusdodge
    @nexusdodge Рік тому

    Insane editing! Great job. Really fun project to watch. I am so glad to know I am not the only one who has to scrap four tries to get something scratch built to work. Thanks for keeping it real.

  • @aninspiredname
    @aninspiredname 11 місяців тому +1

    I can't say how much I appreciate you showing the random hiccups that inevitably happen during a project and give us a sense for how much time a project actually took. It's immensely comforting compared to seeing a project seem to go smoothly on UA-cam only for it to turn into a bear when I attempt it myself.

  • @curm1778
    @curm1778 Рік тому

    Needs handles or lift points (how else do you plan to get it into and out of that car?). Needs lights (you plan to see into it in the dark?). Integrate and get it figured out now and when you make the others you're doing that as part of routine assembly. You go to school on the first one. The rest are just jobs.
    Best EV conversions on YT. Well done.

  • @ErrorProne
    @ErrorProne Рік тому

    super excited to see the final product. its really coming along!

  • @critical_always
    @critical_always Рік тому

    You're a master at narrating and presenting your work.

  • @portalman95
    @portalman95 Рік тому

    lowkey, best series on youtube RN. im always exited to see a new vid.

  • @shinjisan2015
    @shinjisan2015 Рік тому

    I like the subtle change in editing where you show the very end of a process. Another enjoyable editing process, like smash cutting together repeated processes, that you have added to your editing toolbox.

  • @NathanHerzig
    @NathanHerzig Рік тому

    Love this build and your dedication to it. You keep making, I'll keep watching.