[JorgeF]

Hello Everyone. Some time Ago I made a post about an isolation issue I had, it gathered a bit of attention due to the fact that I had replaced a damaged cell in the past and some of you were asking me how. I have been in quarantine for about a week now and decided to do a short video demonstrating what I did. Ill post images so it's more clear.

Keep in mind I'm not a 3d modeler or GM engineer, What I'm showing you is how I came to understand the volt and how it works. Any modifications, replacements and other things you might want to do to your car, please handle it with care and patience.

I apologize in advance for the crappy modeling and bad audio, I've got COVID and this was the only time that I'm having free time at home to make a 3D model and do some sort of explanation. I def. skipped over certain things but I think the main thing which is battery cell replacement is covered in it. If you guys have any questions feel free to ask or DM me if you need help with something specific. More than happy to help.

 

[minorukun]

Hello Everyone. Some time Ago I made a post about an isolation issue I had, it gathered a bit of attention due to the fact that I had replaced a damaged cell in the past and some of you were asking me how. I have been in quarantine for about a week now and decided to do a short video demonstrating what I did. Ill post images so it's more clear.

Keep in mind I'm not a 3d modeler or GM engineer, What I'm showing you is how I came to understand the volt and how it works. Any modifications, replacements and other things you might want to do to your car, please handle it with care and patience.

I apologize in advance for the crappy modeling and bad audio, I've got COVID and this was the only time that I'm having free time at home to make a 3D model and do some sort of explanation. I def. skipped over certain things but I think the main thing which is battery cell replacement is covered in it. If you guys have any questions feel free to ask or DM me if you need help with something specific. More than happy to help.

nic jorge, I found a chinese cell provider that is celling 36ah cell and it has almost the same dimension, my idea is to make a new battery replacement with like 25.2kwh brute capacity and real like 18 kwh or maybe if we can make a new 96s3p with this cell will have upto 38kwh brutal capacity

 

[TYmrLutz]

Another great post JorgeF! Your statement of how its been said the technology being beyond a DIY repair is horsesh*t inspires confidence that Volt cell replacement is indeed not beyond an advanced, competent, workshop repair. Not too much about info regarding safely discharging, measuring, grounding etc., but if one dares to go this far in, electric shock protection is important. I think/hope most backyarders would have sense enough to be aware of the dangers.

 

[JorgeF]

Another great post JorgeF! Your statement of how its been said the technology being beyond a DIY repair is horsesh*t inspires confidence that Volt cell replacement is indeed not beyond an advanced, competent, workshop repair. Not too much about info regarding safely discharging, measuring, grounding etc., but if one dares to go this far in, electric shock protection is important. I think/hope most backyarders would have sense enough to be aware of the dangers.

Absolutely, I plan on making a much more detailed video, I didn't go too in depth with this one due to time and sickness but I'm currently working on a better version o nthe Volt battery model I made in this video to go much more in depth about it all.

 

[Sly Bob]

Great post and I for one am REALLY interested in the forthcoming video. All the best and here's hoping that you can get your fight with COVID behind you soon.

 

[Bushpilot]

Wow, thank you, thank you, thank you, @JorgeF ! I hope to never need to do this, but you have taken away a lot of the mystery. I think I actually could pull it off if needed.

Looking forward to more of the same, from you and others.

Get well soon!

 

[saltsman]

Legendary video! I feel a lot better about being able to swap out segments and cells if needed. The CAD was super helpful. Would LOVE to see more of the actual disassembly and reassembly as more people get into this.

Take care of yourself. Covid can take a while to clear.

 

[Turboman92]

I doubt most people have seen this, but if you guys like JorgeF's video (thank you for that, by the way!) then you'll probably love this youtube channel. Weber Auto. A school that teaches automotive technology. Here is their teardown video on a Gen2 battery. They have info on basically every other hybrid/EV powertrain as well!

Gen2 Battery Video

Main Youtube Channel

 

[JorgeF]

Thank you everyone for the get well wishes 🙏
I appreciate you guys! I'm going to be doing a more in depth video about some of the things I notice about the car with a newer battery model I'm working on that is much more accurate. I will also be posting the CAD file for free so you guys can download It and use it when needed.

 

[volt spain]

Fantastic job Jorge! Probably the future of the few of us who would like to keep the Volt forever... By the way which electrical precautions did you take in the process ? Did you discharge the whole battery or at least the 1 Kw section? Kind regards and all the best with your Covid survival .

 

[JorgeF]

Fantastic job Jorge! Probably the future of the few of us who would like to keep the Volt forever... By the way which electrical precautions did you take in the process ? Did you discharge the whole battery or at least the 1 Kw section? Kind regards and all the best with your Covid survival .

Hey thanks! Yeah It'll be def. the route most of us will have to take to keep our volts as alive as possible. I personally didn't discharge the battery at all when I worked on them. It's important to remember that the battery is only dangerous because all the cells are connected in series, once the cables and connectors are removed the voltage drops to what one cell equals up to. It's also important to remember that you would not be electrocuted if you touch the negative or positive ends of the battery, its only when you touch them both at the same time and complete the circuit by being the ground that you will be shocked. I just made sure I never touched them at the same time and avoided the tops of the cells as much as I could. There are also insulation gloves you can use (I didn't) and it will keep anything from arching.

I've posted the model in this Video, free for all of you to use and breakdown if you need to. However keep in mind this model is not the most detailed, accurate or updated model.
First Generation Chevy Volt Battery. - Download Free 3D model by JorgeF (@JorgeF) [43a3c30] (sketchfab.com)

However I'm currently working on an extremely HD and accurate model which I'll showcase a picture of it here. This model will contain it all at the highest detail I'm able to achieve. My goal with this is to make this battery as DIY repairable as possible, When I was having issue with my own battery initially I remember the horrible frustration of trying to fix it and feeling absolute dread when I found I was alone with this problem, worst of all was calling the dealership service shops and hearing them say they either didn't have the battery segments or whole assembly's and even then it would be anywhere from $14,000 to $19,000. This model, this Idea will make it easier for us to just buy a small 1kwh segment and take what is healthy from that one and replace individuals cells in our home volts for a significantly lower price than what it would cost in a dealership. GM has done what they could to make this battery as hard to work on as possible, Like I've said before so many people told me "Oh the technology is too much- its beyond DIY". Bogus. Hopefully these things have helped you guys, and help anyone else whos going through these problems alone.

 

[Turboman92]

However I'm currently working on an extremely HD and accurate model which I'll showcase a picture of it here. This model will contain it all at the highest detail I'm able to achieve. My goal with this is to make this battery as DIY repairable as possible, When I was having issue with my own battery initially I remember the horrible frustration of trying to fix it and feeling absolute dread when I found I was alone with this problem, worst of all was calling the dealership service shops and hearing them say they either didn't have the battery segments or whole assembly's and even then it would be anywhere from $14,000 to $19,000. This model, this Idea will make it easier for us to just buy a small 1kwh segment and take what is healthy from that one and replace individuals cells in our home volts for a significantly lower price than what it would cost in a dealership. GM has done what they could to make this battery as hard to work on as possible, Like I've said before so many people told me "Oh the technology is too much- its beyond DIY". Bogus. Hopefully these things have helped you guys, and help anyone else whos going through these problems alone.

Where are you able to source the OEM cells from? Do you have a source?

 

[JorgeF]

Where are you able to source the OEM cells from? Do you have a source?

Best way to do it is to buy a small 2kwh or 1kwh segment from eBay and take the healthy cells out of it. You can't buy cells.

 

[JorgeF]

Hello everyone! Today I went ahead and uploaded the new video showcasing the New and much more Improved Model of the GEN 1 Chevy Volt Battery.
(38) Gen 1 Chevy Volt Battery. - YouTube

Model: JorgeF (@JorgeF) - Sketchfab

 

[Sparky88]

Very interesting post. The only thing that I would do differently is how you separate the individual cells. Instead of cutting the cell below the weld spots, I would use a dremel cutting wheel and grind out the weld only on the cell your replacing. That way you have a full surface to bolt or spot weld the new cell to. Otherwise great post...thanks for sharing.

 

[JorgeF]

Very interesting post. The only thing that I would do differently is how you separate the individual cells. Instead of cutting the cell below the weld spots, I would use a dremel cutting wheel and grind out the weld only on the cell your replacing. That way you have a full surface to bolt or spot weld the new cell to. Otherwise great post...thanks for sharing.

Good point it's only 3 weld spots where they contact, it actually leaves plenty of room to work with if you only cut where it makes contact. Interesting idea I prefer it over my original cut and rebolt one!

 

[mars234hall]

Good point it's only 3 weld spots where they contact, it actually leaves plenty of room to work with if you only cut where it makes contact. Interesting idea I prefer it over my original cut and rebolt one!

What happened to the original video?

 

[masospaghetti]

Any update on this?

Also, possible to share the cad model? I am curious what parts would have to be fabbed to build a "new" module with new cells. As I understand it, it would require new plastic frames and new cells but the rest could be re-used.

 

[Steverino]

As I understand it, it would require new plastic frames and new cells but the rest could be re-used.

I doubt you'll be fabbing the plastic frames. They are "exotic" glass filled with extremely tight and precise tolerances.

 

[masospaghetti]

I doubt you'll be fabbing the plastic frames. They are "exotic" glass filled with extremely tight and precise tolerances.

Any theories why they are exotic and glass filled? This is one reason I wanted to see the cad model.