GWL/Power Group - EV & Power Solutions
You can see a lot of their products at: http://www.yttrium-power.com
Disclaimer: I have no affiliation with the company, but they have treated me in a swift and very professional manner.
They did require payment before delivery, which tends to turn on all my alarm bells.... I did quite a bit of research on them (aka googling), and they did seem genuine enough - so I went for it.
They have responded quickly to my (sometimes) stupid questions ;-)
I did recieve a discount for promoting them, so make up your own mind, but I will, and can, recommend them.
It took 35 man hours to remove the batteries, modify the battery boxes and install the cells. The day ende at 11PM with me driving the car home - all the way without stop :-D.
|The car without the 16 lead acid batteries - note how high it stand on the springs :-) You can see pictures from 2006 showing the mounting of the original battery pack here||Some of the lead acid batteries and a couple of the TS-LFP90AHA cells.|
|The rear battery box without the batteries but with the plastic seperation the batteries. The battery box was divided into two parts, but the new 48 of the 64 cells would be mounted in one box.||Rear right corner of the rear battery box.|
|Rear left corner of the rear battery box.||Front left corner of the rear battery box. The box with the wires comming out is the BMaS (Batteriemanagement-System).|
|Front mid section of the rear battery box.||Front right corner of the rear battery box.|
|Left corner without the plastic inserts.||Right corner without the plastic inserts.|
|Full view of the front of the rear battery box without the plastic inserts.|
|Right section of the frontal battery box.||Left section of the frontal battery box. Most of the 2kW onboard charger can be seen to the left.|
|Bulk of the cells - now ready for actual mounting :)||We decided to reuse the fuse mounting and interconnect section of the rear battery box. So the plastic insert was disected and the re-useable part attached to a piece of 18mm plywood.|
|Plastic on plywood.||Plastic on plywood - take 2.|
|Modified battery box ready for the cells - a piece of foam was placed in the bottom of the box.||Read battery box - another angle.|
Cells mounted in the rear box - looks quite good I think. The box is divided into four sections.
The old divider plates was reused and so was the temperature sensor - mostly because it
would be needed by the old battery management system.
The divider vertically plates will be replaced by a solid material in the near future (plywood I guess ;-). The old plates will not be strong enough to withstand the expansion of the new cells (imho).
|A step or two back.|
|The frontal battery box assembly mounted with the remaining 16 cells. Note that the upper left cell was mounted incorrectly - we found out before any harm was done, but it could have resulted in two shorted cells !||This space will be used for misc. electronics.|
Interconnections being mounted. I had prepared a drawing, which was more or less ok for the rear
battery box, but due to pratical considerations the frontal battery box was done a little bit different than planed.
Only half the battery current will pass in the "small" interconnects.
|The finished rear battery box.|
|The almost finished frontal battery box. We did this one first and I had planned to use cables (50 mm^2) in the rear also, but it was hard to make them in the exact length needed (+/- 1mm) so we went for bus bars in the rear (6mm x 20mm).||Kasper Svendsen (black shirt) and Henning Roar Nielsen doing all the hard work while I just take pictures :)|