Eight years ago I installed a pack of 36 Lithium cells in my EV. After about 50,000km and several near-death battery pack experiences (over discharge) the range decreased beneath a useful level so I have just purchased a new pack.
Same sort of cells, CALB 100AH, 3.2V per cell (80km range). The pack was about AUD$6,000 delivered and took an afternoon to install. I’ve adjusted my Zivan NG3 to cut out at an average of 3.6 v/cell (129.6V), and still have the BMS system that will drop out the charger if any one cell exceeds 4.1V.
The original pack was rated at 10 years (3000 cycles) and given the abuse we subjected it to I’m quite pleased it lasted 8 years. I don’t have a fail-safe battery management system like a modern factory EV so we occasionally drove the car when dead flat. While I could normally pick this problem quickly from the instrumentation my teenage children tended to just blissfully drive on. Oh well, this is an experimental hobby, and mistakes will be made. The Wright brothers broke a few wings……
I just took the car with it’s new battery pack for a 25km test drive and all seems well. The battery voltage is about 118V at rest, and 114V when cruising at 60 km/hr. It’s not dropping beneath 110V during acceleration, much better than the old pack which would sag beneath 100V. I guess the internal resistance of the new cells is much lower.
I plan to keep driving my little home-brew EV until I can by a commercial EV with a > 200km range here in Australia for about $30k, which I estimate will happen around 2020.
It’s nice to have my little EV back on the road.