I hate to disagree with Mike, but when I tested the sense resistors (if that is what they are called), they acted like normal resistors. I tried heating a few. They actually started at 180 - 190 ohms and dropped to 160 ohms hot. Is it possible there could be a few different kinds installed in packs? Or could you have mixed up your sense resistor and PTC notes?
Will be interesting to see how the system handles a larger pack and will answer the question of how large of can the Insights BCM go. Also, are you going to let the stock system do some charging? I can't imagine trying to fully charge a battery that size. Just charging under 8Ah seems to take forever
As far as faking out the BCM, if you can use either 40 or 50 cells, then you wouldn't have to as you would have 11 points to tap from (the 11th point is the final (-) if you are counting all (+) terminals. I haven't checked the Insight pack closely, but the Civic pack adds a 12th by tapping both sides of the cut switch. I will know for sure about the Insight wiring when I start my visual load gauge next week
