> I have heard of copper pipe being crushed flat, then drilled, to
> create suitable custom high amp busbars
Beware! Copper water pipe is not pure copper, but is composed of
alloy, you won't be getting the conductivity of 99% copper. Also,
crushing and drilling pipe is time consuming and messy, the drilled
holes can't be properly deburred, and the possibility of
corrosion/tarnish in the sandwiched interior surfaces is real.
>> The only purpose for the stock Leaf busbars was to tie the middle
>> terminals of the paralleled modules together.
> Why would you bother doing that?
These are used modules with a somewhat variable capacity remaining. I
was able to test that capacity and pair weaker modules with stronger
ones, creating a more robust pack assembly. Also, paralleling at the
cell level means half as many BMS channels. You see this as a bug, I
see it as a feature. A failing pair of cells in one module will be
quite apparent in the performance of the tractor, which triggers
diagnostic actions on the part of the owner/driver (me).
Maybe tying the center terminals together with a fuse is a more
cautious approach. Using thin-ish wire would be a similar
current-limiting technique.
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