DIY 48V 24Ah Battery Pack Assembly Guide

If you have any extra disassembled batteries, you can charge them and assemble them into a 4824 battery pack. First, clean up and conduct a test with a nominal rating of 48V 24Ah, but actually measured at 25Ah, possibly due to it being recently produced. Then, purchase a 60A protection board, considering the overrated label, and use it as a 40A board since a typical 48V battery pack uses a 30A board, which is absolutely sufficient. For the housing, a new national standard housing found online can be used.

Proceed with assembly by removing the original FPC ribbon cable.

The battery is filled with glue, so remove it as the bare outer shell is more likely to be scratched, and protect it with an epoxy resin board.

The protection board is still relatively large.

Solder the wires, check for any issues.

Then solder them again, stick the sponge strips, reduce vibrations, and secure it.

Done!