generation 1 prius with gen 2 modules

[statultra]

Success! finally I got around to swapping modules from a 05 and 07 prius HV battery.
The car drives like brand new, the gas mileage has improved vastly. I took it on a 15 mile run and averaged 55.8 mpg. Since i didnt have the battery cover on im not planning on taking it farther.


The only issue is the battery cover.
The 04-09 modules are larger, and im having trouble putting on the battery cover, so in order to fix this im thinking of cutting the original case and extend it 1 inch over the existing width, the sides of the case are pressing against the new modules.

Sorry for the large pictures, two of them are the two gen 2 batteries where the modules have been removed, one where all 28 is removed and another where only 10 have been removed. I have a lot of extra parts, including 38 gen 1 modules ( some are bad ), and 18 gen 2 modules and a gen 2 battery ECU.

Also something interesting to note, the 04-09 modules only have one screw that holds them to the case, versus two screws per module on the gen 1.

[Patrick Wong]

Congratulations!

Did you have to equalize the SOC levels?

Did you drill holes on the bottom of the case to secure the new modules, or were you able to use the existing holes?

I was wondering whether you might be able to use the two 2G battery case covers as raw material to fabricate a new cover for the Classic battery case?

[statultra]

Originally Posted by Patrick Wong

Congratulations!

Did you have to equalize the SOC levels?

Did you drill holes on the bottom of the case to secure the new modules, or were you able to use the existing holes?

I was wondering whether you might be able to use the two 2G battery case covers as raw material to fabricate a new cover for the Classic battery case?

I dont think it would work if i used two 2g covers, reason is based on that big hole for the vent fan, i would have to fabricate that which = more work. I managed to get a few of the modules screws in. It initially didnt match up, until i tightened the hold down bars.

I didnt equalize the SOC levels since each of the modules from the batteries had 7.61 volts.

[hobbit]

That's awesome! I think the new modules even have a wee bit
more capacity, 6.5 Ah vs 6, not that you'll get to really use
it, but...
.
I definitely wouldn't try to squeeze the old cover on, as it would
be trying to crush inward toward all those delicious metal battery
terminals sticking out through your interconnects. But you
probably need *some* kind of cover for as-designed airflow.
.
_H*

[statultra]

Originally Posted by hobbit

That's awesome! I think the new modules even have a wee bit
more capacity, 6.5 Ah vs 6, not that you'll get to really use
it, but...
.
I definitely wouldn't try to squeeze the old cover on, as it would
be trying to crush inward toward all those delicious metal battery
terminals sticking out through your interconnects. But you
probably need *some* kind of cover for as-designed airflow.
.
_H*

i think im gonna cut the cover lengthwise and add filler material to widen it maybe a half inch. OR retrofit the gen 2 case on the 01 prius case.

[Patrick Wong]

Originally Posted by statultra

i think im gonna cut the cover lengthwise and add filler material to widen it maybe a half inch...

That sounds good. The battery case seemed pretty substantial to me, what tools will you use to cut the sheet metal?

Pls take and post photos of the finished result.

[statultra]

i was thinking of clamping the top of the case on two clamps and cutting straight down the middle with a reciprocating saw.