Lead Acid Battery Upgraded to Lithium Iron Phosphate https://hackaday.com/2026/01/23/lead-acid-battery-upgraded-to-lithium-iron-phosphate/
#BatteryHacks #3dprinted #Atv #Battery #Batterypack #Busbar #Ev #Leadacid #LiFePO4 #Lithium #Lithiumironphosphate #Screwterminal
#Busbar
Lead Acid Battery Upgraded to Lithium Iron Phosphate
![<div><img alt="" class="attachment-large size-large wp-post-image" height="450" src="https://hackaday.com/wp-content/uploads/2026/01/lifepo4-main.png?w=800" style="margin: 0 auto; margin-bottom: 15px;" width="800" /></div><p>Lithium batteries have taken over as the primary battery chemistry from applications ranging from consumer electronics to electric vehicles and all kinds of other things in between. But the standard lithium ion battery has a few downsides, namely issues operating at temperature extremes. Lead acid solves some of these problems but has much lower energy density, and if you want to split the difference with your own battery <a href="https://www.youtube.com/watch?v=l-nkiqVb0J8" target="_blank">you’ll need to build your own lithium iron phosphate (LiFePO4) pack</a>.</p>
<p>[Well Done Tips] is building this specific type of battery because the lead acid battery in his electric ATV is on the decline. He’s using cylindrical cells that resemble an 18650 battery but are much larger. Beyond the size, though, many of the design principles from building 18650 battery packs are similar, with the exception that these have screw terminals so that bus bars can be easily attached and don’t require spot welding.</p>
<p>With the pack assembled using 3D printed parts, a battery management system is installed with the balance wires cleverly routed through the prints and attached to the bus bars. The only problem [Well Done Tips] had was not realizing that Li](https://files.mastodon.social/cache/media_attachments/files/115/948/482/286/699/760/original/c0901d8d61304255.png)
What surface finish is appropriate for my #DIY #Busbar ? I'm wondering if I should polish them?
They are 50mm x 6mm Tinned Copper and I'm using 316 Stainless steel bolts with Tinned Copper crimped on lugs (onto tinned Oceanflex cable ranging from 6mm2 to 95mm2)
#Electric #ElectricYacht
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