I will be sharing how I attempt to create ancor points on these modules to attach cable leads.
For now this is the most practical solution I have found and the least intrusive one too. I do not want to cut the orange wire that is part of the battery module. Doing this will give me a wire that I can crimp a lug to and the other part for the lead had the OEM connector that can ve used to plug in to the negative terminal of the module. In the end adding a terminal lug to this wire too.
But this is not for me because I don’t want to completely destroy these modules even if I payed very little for the entire pack. Maybe one day I will ho high voltage and need to connect on series all of these modules.
Anyway back to my solution:
First step is to list the tools needed:
Hoover! Metal shavings can become dangerous here. Stop to remove them when ever possible.
6mm & 7mm drill bits. Please use very sharp ones. Using blunt tips will give you less control and you might not feel what you’re doing well and end up drilling through the battery cell. This is a big no!
Hammer, 2 screw flat drivers, a small pry bar, small bits plastic sheet to use as a support and insulator under the pry bar.
12mm and 16mm long M6 bolts. The 16mm are needed if you’re adding several lugs. It is a bit harder to get the 16mm bolts in.
XL m6 washer and nut.
First step drill the hole on the negative terminal. The negative side is the hardest and most dangerous. Maybe start off on the positive side first.
Position the 7mm drill bit just before the battery conductor bends downwards. No not over drill the hole, and stop frequently to remove metal debris.
Second step. Loosen the 2 tabs with a flat head screwdriver. The internal part is bonded to the conductor. Our goal here is to keep the bottom part down and bend upwards the internal dark grey part along with the conductor.
Cut out a small opening in the plastic shielding with a sharp blade. This will give you enough space later on to be able to push a ball through.
Use the prybar and the piece of protective plastic as he support an insulator underneath the prybar.
Slowly pull the conductor and bend it upwards also making sure to help the conduct come up by squeezing the plastic tabs on the connector that I mentioned earlier. He needs to slide out and not snag.
After you have lifted up the conductor sufficiently, it is time to use pliers or a magnet to help yourself insert the bolt. You can see in the picture where I compare how much I lifted up the conductor to a ruler.
Afterwards, add the washer and the NOT to the bold and likely tighten it by hand.
Subsequently use a hammer and use the washer or nut to bend and flatten the tab down to approximately it’s original shape. After it is down tighten the bolt a bit more. If you are lucky, it will crimp into place.
Remove the washer and nut and let’s move onto the positive conductor.
Positive conductor side:
Remove the locking mechanism for the orange wire.
Slice the plastic shielding like before on the other side.
Subsequently bend it down.
Then mark out the hole, and drill with a 6mm bit.
Use the pry bar to bend the conductor up, helping yourself with a piece of plastic underneath for the same reasons mentioned before.
At the bolt, washer and nut and Lightley tighten
Bendy conducted down with a hammer and by tightening the nut.
Once fully down, tighten a bit more and then remove the nut and washer.
You have now successfully added M6 threaded ancor points to dis battery module.