#E-bike battery repair

I just want to ask, which courier do your fans ship with?

Roughly how much to build a 48V 30A, boss?

Are you in Shenyang?

How much is one of these cells????

How much to re-cell this?

A follower from out of town sent in a 48V Li-ion e-bike battery, label says 48V 15Ah Panasonic cells, made 2023-12; it feels feather-light in the hand, clearly not 15Ah, range is very short and nowhere near the kilometres the seller promised. Off with the top cover: the cells only take up a little space in the middle, the rest is foam padding, the block is very small; inside it’s 18650s, 13S3P, the wrappers carry no brand or capacity info — typical knock-off cells, you can imagine the range; this battery is worth nothing. Rebuild as 15Ah: brand-new EVE 18650s at 2.5Ah each, 6P13S; place them in the holder alternating + up / − up, lay one row first as the reference, mind the orientation and don’t get it wrong; snap the top holder on to make one block; the connecting material is 0.2-thick nickel-plated steel strip cut to the needed lengths; the welder is just an ordinary capacitor spot welder — 18650s don’t need much current; 4 welds per cell to guarantee current-carrying strength; weld the parallel and series links in order, then check the whole block for wrong or missed welds; fit the BMS, charge and discharge test, no problems and it’s done. Warning: when buying a battery, any pack whose cells are labelled CATL, Panasonic and the like is fake. Comments (343): how much for a 48V30A build (2); 12C 25P cell config is overkill, 5C is enough (2, doesn’t match this video); selling fakes is a crime, jail (1); which courier did you use (1); how much for 48V25A; how much to rebuild a Sunra; you can tell it’s only a few Ah just by looking.

Opens with the customer: the battery hasn’t lasted well since 2024, used to charge for three hours, now goes green the moment it’s plugged in. Label says 48V 15Ah, made 2024-09; the problem is it won’t charge or discharge. Opened up: cylindrical 18650s; the case says 15Ah, but the cells are 2.5 each in 4P, really 10Ah; clearly salvaged old cells used a second time, many already leaking; very crude workmanship; he decides to scrap the cells and rebuild with brand-new ones; the only usable part of the old pack is the BMS, removed for reuse. Rebuild: 18650 at 2.5Ah each, 48V10Ah needs 13S4P, 52 cells, brand-new EVE; laid into the holder one group positive-up, next negative-up; series raises voltage, then 4P adds capacity. Welding uses 0.2 nickel-plated steel strip on a capacitor spot welder, settings on the screen (preheat auto 0.05ms, interval 20ms, gear 29, trigger 0.6s, continuous); the process is simple as long as nothing is missed; check for missed or wrong welds afterwards. Fit the BMS, usually on the negative side; pre-cut insulating paper where the sense leads run; tidy the ribbon and weld it to each group’s tab in order — the order must not be wrong; the sense leads monitor each group’s voltage and cut the BMS circuit if it goes too high or too low; to avoid mistakes, after each weld the lead order is checked on a test board before connecting the BMS. Finally the + and − power leads go on, a proper charge/discharge test (49.53V 4.92A), then insulation, back into the case, done. 16 comments: are the EVE 25Ps genuine (print and barcode misaligned); how much for a pack (1); how much for a 48V50Ah for a ride-share bike; how much per cell; are you in Shenyang; the original didn’t even have a holder; what BMS is that small.