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After 24 hours sitting fully charged, battery 1 cells dropped between 4.12V and 4.13V: Battery 2 seems to be weaker, with 3 weak cells:

I think it's at 3.75V that every cells fall in capacity. It has 8AH capacity which is very correct. I'm going to leave it completely charged until sunday and see what happens

it passed the charge no problem: it seems good? Going to wait 24h fully charged to see if there are self discharge issue.

I can get 8 AH out of the pack: I think I should get a new BMS..... Shall I get it from Bestechpower or EvAssemble? Geebee, I always thought it wasn't convenient to cut it with a rotating tool. Like cutting wood just burn the wood and cutting metal just wear so quickly the bits. It's good...

Ok let's wait and pray then.... Oigoi the main case is aluminium. There is no point for me to use polycarbonate as protective layer.

I finally finished balance charging.... pffiiioouuu! I doing a discharge test now: The 2 red cells seem to be slightly lower capacity... but still good? Do you think it's a BMS issue? I'm thinking to maybe just change the BMS to the one sold by Bestekpower.

Oigoi, polycarbonate sheet should not be used as first layer, because it's plastic it just melt under high temperature. Epoxy glass are used because of it's electric insulation, ability to support high temperature and being flame retardant.

Ok so what do you recommend to make clean cut? i haven't found the tool yet

My little discharge trail :) So 0.3ohm * 6 = 1.8 ohm. I discharge at 2.3A or 9W. If the cell is 8AH, it means 0.25C.

I've tried it and the metal plug became red after few seconds... I've looked at it again and realised my resistor is 0.3 ohm and not 3 ohm....... So I've put 60W on my cell for few second. It went down to 4.1V... Let's re-do it

Its rated at 25W so it should handle that easily. I just wasn't sure the wiring is correct I don't want to create a short lol

After 15 hours the balance charge isn't still finished. And I have another pack to repair. I'm thinking to directly discharge the high voltage cell with a 3 ohm resistor. So during balance charge, if I can see 1 cell charging much faster, I should be able to directly detect the faulty cell...

Anyone know where I can buy these epoxy glass sheet for cheap? I've seen on ebay and they all look expensive

Yes I'll check it once it's balance charged. My charger can do that. After more than 12 hours balance charging... it's still far from being finished.... Damn that so long

Thanks dave!

I'll balance charge first. Then discharge it to see if there is any weak cell (i think it probably has at least one). Then replace the faulty cell with the other pack. Then balance charge again and leave it for 24h fully charged to see if there are any self discharge issue. Then cycle again...

So even if I repair it, it's very likely going to fail in the future? I have at home a bunch of zippy compact 9s I could re-wire to 10s and fit perfectly the battery frame: ZIPPY Compact 4000mAh 9S 25C Lipo Pack (EU warehouse) But I'm a bit concern to give lipo to someone without knowledge...

Yes I can find that in but as my cardboard is working fine I thought I could leave it as is. What is a gerbil? I currently have a Proxxon to cut but it doesn't cut big items or very straight

do you know the cells name and specification? Currently I don't even know how many AH it's supposed to have...

I've put all the wires directly to the balance plug lol This is going to be the longest balance charge I'll ever have.... I have cells from 3.7v to 4.15v.... I'm even wondering if it might be a BMS failure to balance?