When I used Calb cells I connected them with copper busbars. https://justanotherevconversion.blogspot.com/2011/07/just-finishing-up.html
The cells had threaded terminals which I used to secure the busbars. Unfortunately I don't remember the size or composition of the bolts and washers. https://justanotherevconversion.blogspot.com/2011/06/just-lego-blockssorta.html Barry JustAnotherEVConversion.blogspot.com On Wed, Feb 25, 2026 at 11:05 AM Greg William via EV <[email protected]> wrote: > When I did my Sparrow lithium conversion I bought a bunch of the Nord lock > washers sized for the CALB cell bolts. I used the copper bars that came > with my 53 cells (I bought a spare). Then I made up a few longer copper > bars out of 1/2" copper tubing, drilled and heat shrink wrapped as > appropriate. Used the remaining Sparrow cables and it all worked well. I > wanted a non-conductive hold down arrangement so used a bunch of the Harbor > Freight large white zip ties. They are about 24" long, 1/2" wide, very > strong and re-usable. Not cheap, though. Then when it was all tested, I > put an inch of spray foam around the base of the cells to avoid vibration > and movement. Cells were all tight up against each other and could never > tell any heat build up charging or discharging. I would do it the same way > again. > > On Tue, Feb 24, 2026, 3:45 AM Jay Summet via EV <[email protected]> wrote: > > > With respect to just "connecting" them, standard cables like you would > > use for Lead Acid batteries work fine, typically with ring terminals (vs > > clamp). > > > > Size the cables based upon your amperage. If you are replacing a lead > > acid pack, I'm going to assume 90-200 volts, and LOTS of amps, so you > > probably want to use 00 welding cables. > > > > Get crimp ring connectors sized for the bolts that go into your cells > > and a hydraulic crimping tool. > > > > However, you may find that the lithium modules are a lot smaller than > > Lead Acid batteries, so need more connections (and the connections may > > be closer together. > > > > Also, many/most LiIon modules need to be kept under compression so they > > don't swell during charging or discharging. > > > > A solution I used was to package up the modules into "battery sized" > > chunks, clamped together (threaded rod through plywood end pieces, > > although you could use metal) with a copper busbar sized perfectly for > > the "clamped" spacing of the modules. You don't want to use a solid > > busbar between modules that can move relative to each other as it may > > rip the bolt/terminal out of the module, but it's OK to do so far ones > > that are physically clamped together. > > > > Then I just used the (flexible) 00 welding wire to connect the > > "batteries" together, much like the original Lead Acid. > > > > https://www.youtube.com/watch?v=PjTwhR-DrqQ > > > > You can find a lot more here by going backwards in age: > > https://www.summet.com/blog/tag/etruck/ > > > > Jay > > > > > > > > On 2/24/26 01:42, Daniel Eyk via EV wrote: > > > I recently sent an email about lithium batteries and I want to thankyou > > for > > > replying as > > > it helped me a lot. > > > > > > I have a followup question about how to hook up the lithium batteries > and > > > what > > > parts are needed to do that. I am used to the old lead acid batteries > and > > > after looking > > > at my battery box, I realized that I don't know how to connect the > > > batteries. > > > > > > Also, someone asked me what kind of lithium batteries I have. They are > > > Calb lithium ion batteries. They have a red cap and a black cap and > > there is > > > a barcode with this number on it. NSA 601305040234. I don't know if > that > > > will > > > help or not in identifying the batteries, but that is what it says. > > > > > > Well, if anyone can tell me what parts I need and maybe cables, I > > > would appreciate it. I did get around $300 worth of cables based on my > > > knowledge of lead acid batteries and hate to lose that value, but you > > > can't have everything. > > > > > > Thanks in advance for any information you can provide. > > > > > > Dan Eyk > > > -------------- next part -------------- > > > An HTML attachment was scrubbed... > > > URL: < > > > http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20260223/a965d6e5/attachment.htm > > > > > > _______________________________________________ > > > Address messages to [email protected] > > > No other addresses in TO and CC fields > > > HELP: http://www.evdl.org/help/ > > > > > > > _______________________________________________ > > Address messages to [email protected] > > No other addresses in TO and CC fields > > HELP: http://www.evdl.org/help/ > > > > > -------------- next part -------------- > An HTML attachment was scrubbed... > URL: < > http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20260225/39cd3928/attachment.htm > > > _______________________________________________ > Address messages to [email protected] > No other addresses in TO and CC fields > HELP: http://www.evdl.org/help/ > > -------------- next part -------------- An HTML attachment was scrubbed... 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