I'd hoped to double the range, keep the weight roughly the same, and not
having to pay more than around $2,000 to get there. That means doubling
the power density (W/ft3), doubling the W/#, and keeping the $/W roughly
the same.
You'll probably need to go with Lithium to double your range.
One cheap way to do it is to buy used, such as a pack from a wrecked
Leaf/Volt. (but even if you get the cells cheaply, you may need to
upgrade your charger and also pay for a BMS system to go with the new
cell chemistry.)
When I purchased a wrecked Nissan Leaf, the batteries ended up only
costing ~ $1000 after I factored in they money made back by parting out
the rest of the car. (not counting my labor.)
However, I also had to spend $1,500 to upgrade my charger and buy an
EVSE, and another $500 for the BMS system. And of course I had to front
the purchase price of the entire Leaf and then get small amounts of
money back here and there as I sold parts.
Jay
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