Stop Buying Expensive Batteries – Build This 100Ah LiFePO4 Pack Instead!

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Daly Smart Active Balance BMS 4S-8S 8S-17S 8S-24S 40A-500A Li-ion LifePO4 Automatically Identify

Stop buying expensive batteries! Build this 12V 100Ah battery pack instead.
In this complete step-by-step DIY engineering guide, Iโ€™ll show you how to build a highly efficient, custom 12V 100Ah LiFePO4 battery pack that outperforms commercial options for a fraction of the cost. We are covering everything from cell compression and custom copper busbars to BMS wiring and heavy-duty load testing.

Whatโ€™s inside this build?
For this project, Iโ€™m using four High Star 3.2V 100Ah prismatic battery cells wired in series. To keep costs down without sacrificing conductivity, I fabricated my own DIY copper busbars. One of the most critical steps in building a custom LiFePO4 pack is terminal protectionโ€”since these cells have one copper and one aluminum terminal, I break down the exact special care needed to prevent galvanic corrosion and ensure a perfect connection.

Because prismatic cells require strong physical compression to prevent swelling and maximize lifespan, I repurposed discarded Action Tesa kitchen wood. Using my laser cutter and engraver, I designed and cut a custom skeleton casing that uses screws to lock and compress the cells tightly together.

The Brains & Testing:
To manage the pack, I installed a massive 250A Active Balance DALY Smart BMS (the blue version) with full Wi-Fi connectivity. Iโ€™ll walk you through the DALY app setup so you can monitor your cell voltage and balance in real-time.

To prove this pack’s performance, I run a series of tests using the Fnirsi BTM24 battery tester. But we don’t stop thereโ€”I also use the BTM24 to run normal, charging, and launch/cranking tests on a 6-year-old DIY laptop 18650 lithium-ion pack and an 8-year-old 12V 342 CCA Amaron car battery!

Finally, we put this 12V 100Ah powerhouse under a real load. Watch it easily run incandescent bulbs, a 12V 20A PMDC motor, and even power a 220V power drill through a 2000W heavy-duty inverter.

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#mrelectron #lifepo4 #lithiumbattery #battery #12volt #batterybuild #batterytester #btm24

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