DIY EV building is becoming become popular, but battery solutions have been limited. The builder must choose between re-purposing used EV batteries of unknown quality sometimes salvaged from a wreck or try to assemble hundreds of cells into a format suitable to their application. Either method is a lot of work and often results in a less than an optimum solution.
Now, by using our CuicPower EZ-Pack and stacking system, you can make the exact battery to suit your project.
The concept is simple: Quickly assemble powerful packs of cells and array the packs using our standardized stacking system and electrical interconnects to build a battery of almost any capacity.
The solution is elegant: The EZ-pack housings are injection molded using a rugged glass filled polyester plastic. The “LEGO” style stacking system supports the assembled packs, and provides a rugged enclosure that can be mounted in multiple ways on your EV. Because the cells are not welded to the EZ-pack contacts, at EOL they can be re-purposed or recycled and the EZ-pack can be reloaded with new cells.
EZ-Packs are the building blocks of our high performance DIY batteries. Each EZ-Pack holds fifteen 26650 Lithium cells in parallel. The internal conductors are made of pure electrcial grade (1100) aluminum and are nickel plated. There is a carefully designed laser cut pattern where each cell contacts the conductor. Small but powerful compression springs between the outer case and the conductor push the contact tightly against the cell terminal so that each cell will make a perfect electrical connection regardless of any minor difference in cell length due to manufacturing tolerances. The system has been extensively tested to ensure it will support a 30C cell discharge rate. EZ-Packs are typically wired in series or parallel/series to build batteries of higher voltage, current and storage capacity.
Our 33 Volt high performance DIY Kart Battery kit has been optimized for Karting. Depending on cell choice, it's capable of long pulse discharge rates up to 450 Amps and short pulses to 750 Amps. A single kit is a good solution for a Kid Kart or driveway toy. A pair of them (66V) will turn any 10kW 48V brushed or brushless motor into a 17.5 kW powerhouse for your track machine or drift Kart. Each kit contains all the necessary components (except for the cells) to build a 150-cell battery. No cell welding is involved, and the battery can be assembled in a few hours using only basic tools. Although a BMS (battery management system) is not supplied, it can be easily connected at the battery terminals or the supplied cell pack interconnects. Please read and understand the EZ-Pack instructions and battery safety page before proceeding to assemble. Cells are sold separately. Email us with a description of your intended use and we'll recommend the correct cells to purchase or you can provide your own. Be sure to check out our quick change battery mounting system which can be found at our sister site www.ekartsupply.com
Our 26650 LiFeP04 battery cells are available in several options to meet different needs.
2.5 Amp hour
This 20C, 2500 mAh, 3.2V LFP cell by PLB is recommended for high performance motorsport applications such as sprint Kart racing, hill-climb cars, drag racing, dirt track, short oval and speedway racing,or other time restricted motorsport applications which require the highest discharge rates..This cell is also tolerant of high level brake regeneration. We recommend this for starter batteries, portable welders and other difficult applications that need the highest discharge rates. It has a short pulse C rate of 50C (125Amp), a long pulse C rate of 30C (75Amp) and a continuous C rate of 20C (50Amp). The 15 of these cells in one EZ-pack can make an instantaneous discharge pulse of 1875 Amps and a 60 second pulse of 750 Amps.
3.0 Amp hour
The 10C, 3000 mAh, 3.2V LFP cell by PLB is a great option for fun Karts, golf carts, the larger arrays used in DIY road-going EV builds, marine applications and standby power systems, This cell 20% has more energy storage than the above 2.5 Amp hour cell and is best suited for medium amperage applications, both in discharge and charge. The cell has a max short term C rate of 20C (60Amp) and a continuous C rate of 10C (30Amp). An EZ-pack loaded with these will make an instantaneous discharge pulse of 675 Amps and have a 60 second pulse of 450 Amps.
They are shipped in cartons of 100.
4.0 Amp hour
This 3C 4000 mAh 3.2V LFP cell by PLB is perfect for large standby power storage arrays and road going EV builds that require large numbers of cells for maximum range. It's also great for other lower current draw applications such as medium duty power tools, power sources for ham radios and other long duration relatively low current applications. A single EZ-pack loaded with 15 of these can make an instantaneous pulse of 300 Amps and 60 second pulse of 180 Amps.
Building a battery with multiple EZ-Packs will require interconnects for the pack to pack connections. Your series/parallel layout will determine how many of each. The simplest and most common layout is a series connection between adjacent EZ-Packs. If it’s to be a single row of EZ-Packs, the long interconnect is all you’ll need. If your layout uses multiple rows, you will need a short interconnect for each crossover connection. There will always be one fewer interconnect than the number of EZ-Packs in a simple series connection scheme. In a parallel/series configuration please note that all interconnects are short. If this layout is intended to deliver more current, then it may be a good idea to stack two interconnects for the series connection. Since the interconnects are fusible, it’s good to have some spares handy. If the interconnects get hot during use or change color, that’s an indication that suggests doubling. Fusible Interconnects are sold in packs of five.
Our EZ-Pack and Stacker system allows you to build batteries of most any size. Stackers are machined from 3/8" polypropylene and have holes that mate with the EZ-Pack bosses. With just two Stackers you can create a series connected battery with a single row EZ-Packs. Two 14-inch Stackers will support four EZ-Packs to make a 12V battery. A 12V battery can also be made with three 7-inch Stackers (2 rows of two), making a square battery with the same profile as our upcoming CuicStart product. The Stackers can come with mount points built in and handles. Tie-Bars and barrel nuts hold the sandwich together. Each EZ-Pack adds 3.25 inches of length or width. Talk to our tech team to customize a battery for your application. For those who desire to create their own Stackers, please refer to the dimensioned print for hole spacing.
Do you have questions about our products or need help deciding which battery solution is right for your project? We're here to help! Fill out the contact form below and one of our battery experts will be in touch to assist you. We take pride in providing top-notch customer service and are committed to helping you build the perfect battery for your project. Don't hesitate to reach out with any questions you may have. We look forward to hearing from you!