Battery pack replacement development thread

[Randy960]

With all Spark EVs now out of warranty, we are all on our own to deal with our aging high voltage battery packs. The options are rather slim, due to the low production numbers of the car, and GM seemingly forgetting they made it at all.

Greentec sells a remanufactured pack for $12.5k
https://www.greentecauto.com/hybrid...h9Ld_D8TBsiuaJePILXCw-z7TcXwtzVrvzL8TUXEuOJ8c

EnerZ seems to be either a scam or they're selling used packs for $3.5k
https://enerz.us/products/2014-2016...ORaU6iA4wiGy19SFekZnj2rMIAP_D4zxoCIt4QAvD_BwE

If anyone sold individual modules, we could at least get an EV shop to swap out modules, but there's no new ones and only rare used ones on ebay. So as things stand, there is no long term solution to keep otherwise working Sparks on the road, unless you've decided your Spark is worth as much as a used Bolt to you. We are a small enough market that I don't see an aftermarket solution coming to save us either.

My ideal solution would be to rebuild the modules with new, higher capacity cells, and add active cell balancing. Then the rest of the pack and harness could remain unmodified. The Spark would then be functionally the same, but with maybe something like 25-30kwh.

Another possibility would be taking modules from a different vehicle and adapting them to fit inside the stock case. Something like the BMW i3 battery looks like it's close to the right size, but I don't have enough measurements yet to see if this is really feasible. If they physically fit, then cooling becomes the challenge.

The easiest way to get off the shelf modules and cooling solutions is to use VDA battery modules. There are aftermarket cooling plates that give them different mounting options, but again I have to do more measuring to see what would fit.

I intend to keep researching, and I'll add whatever I find here. Feel free to add any ideas, or information you have. I also sent a long, slightly angry email to GM requesting that they at least share information with us, and I'll share any response I get.

 

[Randy960]

Thread about adding active cell balancing.

https://www.mychevysparkev.com/thre...atteries-active-balancer-during-driving.9561/

 

[jef]

I still have my Spark EV with 5 of the modules at 80%. 1 module has a bad cell. The car is in too good of shape for me to have it junked. It's drivable with 53,000 km (33,000 miles) on it. I do need to do something with it as I live in a condominium. Anyone in the Metro Vancouver area have any ideas or need for it?

 

[h71]

Someone on the spark ev group on fb posted about rebuilding the battery pack, he was from the middle east, can't remember where. The car was a USDM vehicle, no idea how it got over there. He had replaced the cells with catl pouches but was informing people as he was planning to offer rebuilding services(?), I asked a few questions but he was very tight lipped about how it would work or what he did. He had some pictures of the dash display showing something like 183 km, or about 113 miles with higher capacity cells. I might have the screen shots of that post somewhere, I'll look later, again, he included no technical information.

 

[BigGuyTinyCar]

You may have to resort to buying another Spark EV as a "parts car" just to have spare modules (not to mention all the other parts that could be useful in the future). Even when a Spark EV bites the dust, odds are it still has 5 good modules. A corollary to that is anyone whose Spark EV HAS bit the dust, you probably still have 5 good modules, so your seemingly "worthless" Spark EV could actually still have significant value to other Spark EV owners.

 

[Randy960]

You may have to resort to buying another Spark EV as a "parts car" just to have spare modules (not to mention all the other parts that could be useful in the future). Even when a Spark EV bites the dust, odds are it still has 5 good modules. A corollary to that is anyone whose Spark EV HAS bit the dust, you probably still have 5 good modules, so your seemingly "worthless" Spark EV could actually still have significant value to other Spark EV owners.

Yeah, they pop up on IAAI and other auction sites temptingly cheap, and I might go that route. Previously I saw the occasional whole battery pack on ebay for like 2k. That would be ideal for me, because I could mix and match the best components into 1 working pack, and use the rest as the base for a project I can take my time with.