In this comprehensive tutorial, Micah from EbikeSchool.com demonstrates the intricate process of constructing a custom 72V lithium battery pack for a 1969 Honda Sports Cub electric motorcycle conversion. Using hexagonal battery cell holders and LG MJ1 18650 cells, he meticulously builds a battery with a 20s12p configuration, resulting in a 72V, 40 amp-hour (2.88 kWh) pack. The build involves carefully selecting and testing cells, using nickel strips for series and parallel connections, and employing a spot welder to create precise electrical connections. To maximize space efficiency, Micah designs the battery to fold in half, strategically placing the Battery Management System (BMS) and using techniques like plastic sheet protection during welding. The video provides a step-by-step guide covering cell arrangement, welding techniques, parallel and series connections, BMS integration, and final heat shrink packaging, offering valuable insights for DIY electric vehicle enthusiasts interested in custom battery pack construction.
