This is coming together so nicely. Remember back I bought a 2013 LEAF. I dissembled the battery from that LEAF for my Electrek, but I kept all of the other parts. The busbars and all wiring looks identical to that of my 30kwh pack. So that means I can use the busbar assembly and bracketry that I saved from my '13 pack to build two identical stacks of 24 modules from my '17 pack. After that I just need to adapt the BMS wiring. That saves me tons of labor drilling and cutting busbars and makes for a super clean, OEM setup. Thanks Nissan! I'm glad I saved all this stuff!
I took the left and right stacks and built them into a long 24 module stack. I will need to think more about how to secure these modules. There is a lot of mass here, maybe 150lbs or more, and it is really only supported by 4x M6 all-thread studs. The OEM stack has a different type of module for half which have studs built into their case which tie into more bracing within the pack. Since my new stack doesn't have these studs, and there's no way to add them, I will have to add bracing another way. I have a few ideas I'll see what makes most sense as I go. If it were a sports car I could be more relaxed, but since it is a 4x4 that will be thrown all around while rock crawling or whatever I need to really do this right.
I also want to maintain all of the original hardware from the battery pack. Well, it's not that I want to but I must. That's how the Resolve-EV controller works, with all OEM hardware in place. So I will keep the service disconnect, current sensor, both contactors, etc and somehow mount them in/on/to my battery box.
My new stack:
OEM rear stack:
If you look closely you'll notice the busbar assembly (orange plastic and copper) I installed upside-down from the original one. I flipped it so that my + and - on each end line up for shorter overall wiring. So easy!
Using my left over brackets to compress the modules. LEAF modules MUST be compressed during use or they will expand and destroy themselves! I measured the exposed thread on the OEM studs and tightened these until they matched.
The BMS wiring saved and labeled ready to transfer to the new pack. I will be extending/shortening the wires as necessary for a clean install.