2008 Mini Cooper clubman s conversion

Some jurisdictions require fuel lines to also be removed for the car to be registered as electric. I think that's what those are running down the tunnel?

Lithium won't solve the problem of you undersizing the current delivery capability of the battery by design.

Undersize cells drop

What's the max voltage on your controller?

You could run 6 modules and set charging to a max of 3.6V per cell group (130V pack) 😬

If it was me, I'd sell the old controller and get one that handles the full SoC 6-module stack voltage.

Yeah, but you're offsetting it with the sale of the old controller, so not horrible. More range, more speed (maybe) might be worth it, despite an extra 55lb.

I don't see the big deal in unevenly splitting the modules. Maybe someone else has a strong opinion for not doing it.

It could matter for the BMS...it might interpret the connecting cable drops between two boxes as a high/low top or bottom cell during highway operations and consistently screw up cell balance to where a module will fail out early relative to its sisters, since some BMS may only take one wiring tap for each cell level in the battery stack.

Cell balancing voltage measurements can't be made correctly where there's a long power cable in a cell voltage measurement loop and during power draw from the pack.

This may not be a problem if the Tesla BMS boards are used to make measurements within its own Tesla module.

I doubt many people give much thought to this.