Thank you for sharing your specs RW. This is promising news for both of us, and anyone else using an 11HV I think that in the end we will both have plenty of power at our disposal.
I have ordered some toggle clamps and nylon thumb screws from http://mcmastercarr.com
to build out a cell testing board. I've also ordered another two PL6's, so I will now have four total. This should speed up capacity testing considerably. I should have the 'board' setup in a couple days.
I have now firmly decided that I will only be charging my cells to 3.6v so I will be doing a 4p98s design. I like what Kerry Mann has done with his battery design, and will be doing something very similar, but for me there is a bit too much exposed conductive material. I'm fortunate to have a laser cutter at work and we do a lot of work with Acetal POM sheet. I'm looking into using POM or a smiler engineering plastic as an external insulator for my battery groups. I am also thinking about potting the the connections to help reduce flex. While doing research last night I stumbled upon http://www.bricolagefaidate.com/english/magicjoint.php
Looks promising and warrants more research. Interestingly this product is "re-enterable" so it can be torn apart pretty easily and a particular cell could be accessed with relative ease. Seems as thought some other products from this company may be applicable to EV'ers as well, such as their self regulating heating cables.