One thing to consider when you downgrade battery capacity while the 
vehicle's daily mission stays the same: your battery cycle life will 
decrease, because you'll be using a greater percentage of its capacity each 
day.

I don't know what salvaged or new Leaf and Volt batteries go for, but IIRC 
the last time I checked, the best price I found for bare Chinese lithium 
iron phosphate cells was about $1.25 per amp hour.  Thus a 100 amp hour, 
3.2v cell would cost $125 plus shipping.  A 34 cell, 108v battery would be 
something over $4200.  

Meanwhile, a new 108v lead battery will cost between $1400 and $2400, 
depending on brand, capacity, and your location.  Most likely you'll be able 
to pick it up locally, so you won't have to pay to have it shipped.

Since the LiFePo4 battery is apt to last at least 3 times as long as lead, 
it would seem that you're money ahead with lithium.  This is what the 
several lithium proponents here on the EVDL will argue, quite persuasively, 
sometimes even rather stridently.  

But once you've bought your new lithium cells, youi're not done.  You still 
have to pay for:

1. Shipping.  This can add hundreds of dollars, and possibly weeks of 
waiting, to the lithium price.  

2. BMS.  You have to choose from different types.  Which is best?  The EVDL 
should be able to help..

3. Probably a new charger.  

4. Rebuilding or modifying your existing battery boxes or racks to 
accommodate the different battery shape and size.

5. Modifying the car's suspension, which is (or should be) tuned to a 1200lb 
lead battery.

6. Your own time and labor, or someone else's, studying how to do the 
upgrade, and installing it.  

OTOH, if you buy new lead batteries, it's way simpler.  You remove the old 
ones and take them to the battery dealer as cores, pick the new ones up, 
bring them home, drop them in, connect them, and away you go.

Here's an interesting lead vs lithium comparison written by US Battery, who 
of course want to defend their lead batteries:

http://usbattery.com/lithium-vs-flooded-lead-acid-batteries/

I have some problems with it because they're trying to argue that three 12v, 
150ah batteries will deliver 750 cycles.  IMO that's way too optimistic. 

However, six USBMC 2200s are much more likely to return those 750 cycles 
with good care, and they're only about 10% more than the price USBMC give 
for the three 12v batteries.  So even if you increase their bottom line cost 
per kWh for lead to 13 cents, and assume that lithiums aren't as expensive 
as USBMC claim, lead still costs about half as much per kWh delivered.

Don't get me wrong, lithium has significant benefits, including lower 
weight, better range, and a flatter voltage curve on discharge.  But lead 
batteries are still the cost-per-mile champs, though their margin has 
narrowed over the years.  

The bottom line is that if lead batteries meet your vehicle mission needs, 
and you've been satisfied with them, I don't see any particular reason for 
you to change to lithium.

That said, I don't think I'd recommend downgrading your capacity, for the 
reason I gave above.

Let us know how it goes.

David Roden - Akron, Ohio, USA
EVDL Administrator

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