SURRON DIY 80V / 29kW BATTERY PACK BUILD – HOWTO

0:00 Introduction
0:29 Organization of This Video
1:48 Pros Why DIY Build a SurRon Battery Pack?
3:48 Cons Why Not DIY Build a SurRon Battery Pack?
8:44 Nickel Strips vs. Bus Plates
10:52 Cost Example for DIY 72V Pack
14:04 Brief History Of The Surron Pack
19:37 Why use 21700 cells, if the Surron is not designed for them?
20:55 Figuring out cell layout
22:40 Why you shouldn't glue cells together
25:50 Finding a case Huge problems
29:04 Cell Holders/Spacers for 20S / 22S 9P
30:03 Cells & Copper Bus Bars Choosing & Finding
31:50 Searching for Copper/Nickel Bus Bars
35:00 Paper Insulators Needed?
35:00 Build Process Photos
41:30 45 Second HowTo Build a SurRon Pack
42:17 The Actual Build Process Video!
44:55 Best 21700 Cells to Use for a Surron Battery Pack
46:45 Is the cost savings worth the work?
47:13 After all the Work, $1000$1400 For Labor Is Not Too High!
48:35 Solving the Bus Bar Problem
53:00 Links In Description to Buy Components
56:07 Parts Start to Arrive, Cells Held in Customs
57:38 Copper/Nickel Bus Bars Arrive
58:39 V1 Metal Cases Arrive
59:00 And, Get Ready for the Big Letdown..
1:00:30 Next Problem... 575A BMS Doesn't Fit
1:01:50 Finally ready to weld!
1:06:00 3DPrinted Case Arrives
1:08:50 Starting to Weld
1:13:12 Connecting the 2 Bottom Bus Plates
1:16:36 Connecting the BMS wires
1:20:30 Fiberglass Sheets
1:23:15 How the Case Fits in the Bike
1:24:50 Soldering B+ and B wires
1:26:20 Important Notes About ANT BMS Setup
1:28:10 Finishing Details & Tips
1:32:52 The Finished Battery Pack

First: Sorry this video, again, is (just a bit) long! Tried to make it as brief as possible but it covers a very involved 4month research and build process. And, some things I repeated, sorry about that.

This covers the process of researching, finding components, and DIY building my 29kW, 80v nominal (92.4v fully charged) 22S9P highpower Surron battery pack. (Note same steps apply if you're building a 60v, 72v, or 80v battery pack and for the Surron or Talaria.)

There wasn't a whole lot of info about DIY SurRon pack builds online, so I thought I'd document the process. The Surron pack requires some specialized parts, and is supercompacted into the available space, so it's been the most difficult pack to build of the 15 I have done since 2015. Yes, you can save over $1000 by building the pack yourself, and yes, it's satisfying to complete, but I do NOT recommend building the Surron pack as your first battery build. Do some simple packs, and study battery theory, first before trying this.

Pack Specs:
22S9P / Samsung 40T / 21700
80V Nominal / 92.4V fully charged
36Ah, 2880 watthours
Max 315A, 29.1 kW

COMPONENTS USED FOR BATTERY PACK:
Cells Samsung 40T 21700:
https://www.imrbatteries.com/samsung...
https://www.nkon.nl/ru/samsunginr217...

BMS Ant BMS 822S 130A Continuous / 325A Peak:
https://a.aliexpress.com/_EIsyz69

Bus Bars/Plates Custom Copper/Nickel Bus Bars (22S9P/20S9P):
https://coolwatts.co/products/Copper...

Cell Spacers Custom 21700 Offset Spacers for 20S/22S 9P Configuration:
https://coolwatts.co/products/CellSp...

Case Metal 160x139x420mm (Fits Talaria):
https://coolwatts.co/products/MetalB...

Case Metal 160x139x420mm, Diagonal Cut Corners (Fits Surron):
https://coolwatts.co/products/MetalB...

Case 3D Printed 158.5 x 136 x 422mm, Fits Surron Free .STL Files:
https://drive.google.com/file/d/1voKe...

Welder I Used MinderRC DH30 MAX V2:
https://a.aliexpress.com/_EJ4nVTB

COMPONENTS FOR MY 29kW FRAMEUP SURRON BUILD:
**Coming Soon

I'm adding chapters to make the video easier to navigate. If you want to skip ahead to the building process clips, feel free, I know it's long.

Feel free to leave comments and questions; I'll try to answer any questions.

Thanks for watching!

My old channel, with 72v BBSHD and Tangent Ascent videos:
CALIFORNIA ELECTROBIKE UKRAINE
‪@californiaelectrobikeukrai5074‬