There has been some discussion off list about building a duplicate of Peter Perkins' original design for a replacement pack for his Generation 1 Insight out of fifty A123 20ah prismatic pouch cells.
I have dubbed this project the PP50.
Peter has been running his original PP50 (lets call it Version 1.0) since 2010 with zero issues.
I will work on building a single Version 1.0 PP50 here in the US.
(It will actually be Version 1.5 PP50, since it will have a minor BMS board update)
We can share the process of that buildup with everyone.
By the time we have it completed we will be that much closer to Peter creating Version 2.0 which will have a consolidated Master/Fooler/Interceptor/Charge Controller and other updates.
After that, THEN, we could move forward with a distributed group build of a bunch of these systems.
Some basics about PP50:
The PP50 replaces the original battery pack with a hand-built lithium pack that retains the stock case and weighs about the same, but has more energy density.
It is intended to be grid chargable.
Everyone should read and look at every one of Peter's pictures in his original build thread. It will give you a high level view of what is involved as well as some great visuals of what the end result will be. A123 20ah Lithium Install
We will need fifty (50) of A123's 20ah prismatic pouch cells with full tabs.
Image of one cell Data Sheet: 20Ah Prismatic Pouch Cell
Currently, cells cost between $25.50-$40 apiece depending on vendor, shipping costs, and availability. ~$30 is most common.
So 50 cells would run between $1,275 - $2,000
Rough estimate of additional items required $2,000 which includes:
- Original Insight battery casing
- Peter's custom BMS
- An appropriate charger to grid charge the pack regularly
- *Peter's BCM Interceptor
- *Peter's BCM Foolers
Lots of other little bits, bolts, connectors, etc
The original casing is modified/cut and will not be able to be turned to its original form factor.
*Peter is looking at combining these separate boards into single board. The system works fine with them separate, but combining them would ease installations.)
Optional. Having Mike Dabrowski's MIMA system will greatly increase your ability to get the most out of having the PP50 in your vehicle.
We are lucky to have Peter as the original trailblazer on this project and his initial work will help give us a head start.
But we don't underestimate the time, effort, and money involved.
It will take several months and several thousand dollars.
Prices are subject to change.
We are doing this for the enjoyment of it and the ability to avoid having having to mess around with the stock batteries.
Parts List in work for all boards
Mini BCM Interceptor
Mini BCM Interceptor thread
Mini BCM Interceptor Parts List
9-10-12 Mini BCM Interceptor parts list with prices. Compiled by rothnic
25 Cell Slave Board
25 Cell Slave Board Thread
Full Size Schematic
Note: Schematic is wrong, use 12F683 PIC
We will be using the V2 Master Board
BCM Fooler Post
Remote Receiver option (optional)
Schematics for switch could not be uploaded since I can only put 4 attachments on this post. See this post for the schematic.