HiLux144
For clarity I am talking about the way to parallel the modules into three parallel modules that are connected in series with three more parallel modules connected in series---- Such that you end up with 16 units of three modules, Like Brian said that gives 16 modules in series (16x7.5=120v) and the amperage for each three modules in parallel is 3 time one module.
In order to do this you have to reconfigure the packs - it is not hard but does take some thought. You have to take the packs apart and rearrange the modules
Here is a picture of the connection part of my 90-96 Volt pack in my truck. This is only two modules in parallel but you can add another module to make three.
The trick is to watch the polarity of the modules - they have a positive and negative terminal and a tap middle terminal -you want the negatives and positive terminals to be the same way for the parallel of the first modules where I have two you will have three.
Mine starts where the cable comes in on the lower right corner and there is a two hole connector that connects the negatives of the first two modules and then going up a two hole connector connecting the tap screws. The second set of double modules is reversed so the bottom side is positive and top is neg.. There is a four hole connector that connects the first two modules positive together and connects to the second two modules negative terminals- this puts the first two modules in series with the second two modules. There is a two hole connector that connects the second two modules tap screws together- only those two modules tap screws- you get a short if you connect to the first double modules. On the bottom side of the second two modules is the positive terminals - connected with a 4 hole connector to the negative terminals of the third set of modules. this repeats On to the last double module which has a two hole connector and a power connection from it.
In a triple parallel module set up you would have a three hole connector to start the three negatives with , a three hole tap connector and a six hole connector connecting the positives of the first combo module and the negatives of the second three module combo.
As a note- the BMS works at the cell level- the 4 volt level - so the BMS would go from negative terminal connector to tap connector and tap connector to positive- at terminals that are 3.5- 4 apart. Thus each combo modules need two bms connections so for 16 combo you would have 32 BMS taps.
If you draw it out on paper it should make sense.
I think I would do two packs of 8 - triple combos and then put them in series. One pack you should be able to make using the existing structural plates of the half battery pack. The other pack will take some more structural work. I can help you get the orange safety covers that mine has although I think Kevin modify the existing leaf covers.
I hope this is understandable.
Here is kevin's again
http://www.diyelectriccar.com/forums/showpost.php?p=805713&postcount=7