|Beautiful 1.5kg 10Ah LiFePo4 Battery inc Carbon Seven Cover
Lithium battery technology can be a touch confusing at times, so for a clear overview this article is good at explaining everything. The battery is built with A123 Cells with a balancing module inside which means it is used just like a normal acid battery. The battery can be charged with the standard alternator but for a complete recharge this CTEK charger should be used (which I have purchased).
It is recommended in Caterham installations to have a battery master cut off switch because the Caterham electronics have a tendency to drain the battery (just a bit) when the car is not running, and as the the battery capacity is lower, the battery will discharge somewhat faster.
During the winter, it is recommended to put the battery inside the house but that is the same as with normal acid batteries (I'm not going to bother though). A big plus of LiFePo4 technology, is that the battery self discharging (while not plugged into anything) is much lower than the discharge rate of an acid battery and also the lifetime is a longer too.
|Original Banner Battery and tray weighed in at over 9kg!
|Odyssey Extreme Battery with Bespoke Cage and Housing in Caterham R500
|My partially home-made carbon housing for the PC680 battery upgrade.
|A 10Ah LiFePo4 Battery that weighs less than 1.5kg, has it's own cage and a beautiful CNC cut Seven Carbon cover
I stumbled on a slight problem though, as there just wasn't quite enough space (due to the red bolt on the right of the picture below).
|With the initial 'portrait' carbon cover the battery wouldn't quite fit where I wanted it to
This took a couple of weeks to come through, and now it was time for the full fitting!
Firstly I test fitted everything, measured and lined everything up - this seemed to take an eternity as I was desperate to get the battery in, but I took my time as I wanted to do a good job. Upon having everything test fitted and happy with where the final battery position was going to be, I thought I'd just double check to see if the engine turned over ok on such a small battery (it doesn't seem possible that it could) but it did; with flying colours too - as good as, if not better than with the PC680 battery!
|Test fitting of landscape topped battery cage and wiring in progress
The rivnuts naturally required riveting into the car, and as I wasn't entirely sure what was below the panel I had decided to rivnut into, I thought it wise to remove the panel. But to get access to all the rivets in the panel the heater element and fan had to be removed.
|Heater element and fan needed removing to get access to all the rivets holding the metal panel below secure
A little over a year ago, one of my rear wings was knocked off by an X5, which meant I needed to fit some rivnuts, and bought this rivnut tool. The rivnut tool is required to fit the four rivnuts that the battery cage and ProBolts fit into, and the picture below is of two rivnuts in, with the other two holes for the final two rivnuts (which will be fitted when the panel is back in the car). Incidentally, for the supplied rivnuts you'll need a 9mm metal drill.
|Two rivnuts in, and the other two holes for the final two rivnuts
|CTEK charge leads, spliced and fitted to battery housing with plug around the rear carbon post
|Final test fit of battery, cage, CTEK wiring, all mounted to metal plate prior to leading edge rivnut fitting.
|Leading edge rivnut holes being drilled - no going back now!
|Sealey CP312 14.4 V 1.8 Ah Cordless Riveter takes the pain out of endless riveting
|Final leading edge rivnut going in
|10Ah LiFePo4 Battery fitted to my Caterham R500 and it looks amazing and only weighs 1.5kg!
Email: firstname.lastname@example.org and phone number : +49 176 322 435 73.
Carsten is also the chap that fabricates the Carbon Handbrake lever, amongst a number of other cool items.
The battery manufacturers recommend to use the 10Ah battery for 2 litre engines with high compression ratios like the R500 etc but Carsten is aware of a few people who use the 7.5Ah battery on a 2 litre car too. So some of the decision is up to you... The weight difference between both batteries is roughly 300g (the 10Ah being heavier). To be on the safe side the recommendation would go with the 10Ah battery for R500 and 485, 2 litre (Duratec) engines and also the 2.3 from the CSR. All others should easily be able to use the 7.5Ah battery.
What's the cost:-
7.5Ah Battery: 199 Euro
10Ah Battery: 239 Euro
Battery Tray: 129 Euro (for both versions with the CNC cut Seven in either portrait or landscape)
Custom covers are also available for 20 Euro. I'm well informed these batteries can be fitted to any kind of cars and are running really well in Lotus Elise's, other sevens, Porsches etc.
Bang for your Buck:-
At 368 Euro's (plus shipping) this upgrade on the face of it seems like quite a lot of money... But... and to put it into context, the cost is around £320 (based on today's exchange rate) and the weight saving is over 7.5kg which works out to approximately 4p per gramme saved! Which no doubt makes this the most 'cost effective' lightness improvement to date and MUCH cheaper than my carbon fibre bonnet :-)
I hope it won't be too long before lightweight battery tech like this is standard Caterham componentry, as given the massive weight saving on offer, I think it should be.