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The electrified Mustang Ford should have made… S550 Mach-E build project
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zackmd1
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- #153
Battery has been acquired! (just needs to be delivered now...)
Polestar 2 long range battery. 27 LG Chem modules in a 4s3p arrangement. 78kwh, 350kw output. The OEM arrangement of the battery modules in the rear of the pack almost perfectly fits in the Mustang. This would allow re-use of the OEM bus bars and more importantly, cooling plates.
Due to the voltage limits of the SDU, I'll likely be dropping the pack to 24 modules for a total of 69kwh. Total weight of the modules themselves should be around 700lbs so I would expect the total battery pack weight to be around 800-850lbs. Potential pack arrangement below.
With the pack acquired, a lot of the specs can be "finalized"
AWD
~330kw output (slight drop due to the removal of 3 modules for the SDU)
~425hp to the wheels
~3900lbs weight
~3.5s 0-60
~240 mile range
Polestar 2 long range battery. 27 LG Chem modules in a 4s3p arrangement. 78kwh, 350kw output. The OEM arrangement of the battery modules in the rear of the pack almost perfectly fits in the Mustang. This would allow re-use of the OEM bus bars and more importantly, cooling plates.
Due to the voltage limits of the SDU, I'll likely be dropping the pack to 24 modules for a total of 69kwh. Total weight of the modules themselves should be around 700lbs so I would expect the total battery pack weight to be around 800-850lbs. Potential pack arrangement below.
With the pack acquired, a lot of the specs can be "finalized"
AWD
~330kw output (slight drop due to the removal of 3 modules for the SDU)
~425hp to the wheels
~3900lbs weight
~3.5s 0-60
~240 mile range
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zackmd1
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- #155
Oh what fun it was to disassemble this thing.... These packs are NOT meant to be serviced even though the modules themselves are serviceable. Got to clean, inspect, and test each module now. Junkyard left the service disconnect off and had the battery outside so it had a bit more condensation then I would like under the cover...
PS: I'm still here, no burn marks from a sudden jolt of electricity....
PS: I'm still here, no burn marks from a sudden jolt of electricity....
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Mike Pfeifer
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Was the lid bolted down? Or maybe riveted down? Glued? All of the above?Oh what fun it was to disassemble this thing.... These packs are NOT meant to be serviced even though the modules themselves are serviceable. Got to clean, inspect, and test each module now. Junkyard left the service disconnect off and had the battery outside so it had a bit more condensation then I would like under the cover...
PS: I'm still here, no burn marks from a sudden jolt of electricity....
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zackmd1
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Bolted! Then sealed with what appeared to be windshield urethane…. So glued as well….
The real challenge came when removing the modules… They used a ton of blue loctite on the bus bar bolts and the captive nut underneath was only held in with a thin plastic panel. So needless to say, a lot of the bus bars got stuck because the nut started spinning. Definitely not designed to be disassembled with that loctite. I’ll have to come up with a new captive nut solution.
Also had a massive amount of thermal compound on each module that again acted as glue so challenge separating them from the cooling plates.
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Mike Pfeifer
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- 2019 Ruby Red Mustang GT A10
It’s really super interesting to see how other manufacturers put these battery assemblies together. I have been with BMW for a long time and I know they have tried a few things as well. I think only the Mini EV has a glued cover, but I’m no expert on Mini. I try to avoid them.
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zackmd1
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- #160
Yeah this battery is a weird combination of serviceability… individual modules, captive hardware on the bus bars, separate cooling plates, etc… but then glue on the top cover, loctite on the bus bar bolts, and essentially clay that acts like glue for thermal compound…
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zackmd1
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The score card so far…
Out of 27 modules, 3 potentially bad modules due to a loss of isolation and 3 modules that pass but are worse then the other 21. Of those three that pass, two are worse isolation results and one is outside of what I would consider balanced (15.74v versus 16.09-16.17v). Going to do a bit more testing and test each cell group next on all viable modules. Condensation is not friendly to batteries…
The minimum module count needed is 21 so as long as no others fail more advanced tests, I should have what I need. The goal was 24 modules however.
Out of 27 modules, 3 potentially bad modules due to a loss of isolation and 3 modules that pass but are worse then the other 21. Of those three that pass, two are worse isolation results and one is outside of what I would consider balanced (15.74v versus 16.09-16.17v). Going to do a bit more testing and test each cell group next on all viable modules. Condensation is not friendly to batteries…
The minimum module count needed is 21 so as long as no others fail more advanced tests, I should have what I need. The goal was 24 modules however.
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zackmd1
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Doesn't look all that big once you stack them nicely....
Final tally is 22 modules with good voltage and high isolation. 1 module is slightly out of balance so need to determine if its fixable or due to a weak cell. Load test next for that cell. Had to discard 4 modules due to loss of isolation. Not bad I think for a $900 purchase on eBay.
Final tally is 22 modules with good voltage and high isolation. 1 module is slightly out of balance so need to determine if its fixable or due to a weak cell. Load test next for that cell. Had to discard 4 modules due to loss of isolation. Not bad I think for a $900 purchase on eBay.
