Bikini Pack

Details on our 75s6p Bikini pack design (Hill climb configured Saker will have three of these).

Copper foil from McMaster: 2" wide x 0.007" Thick (±0.001") - we need about 150'

FR4 USA source and China source (Bob uses 0.025" sheet for general pack isolation but 0.125" for more rigid requirements).

Estimate the individual cell fuse to be 8.7mm x 5mm long.

Fuses we are using:
 * A50QS350-4 500V 350A
 * A100P300-4 1000V 300A

Actual parts List:
 * 1 x A100P300-4 1000V 300A Fuse (main pack fuse)
 * 1 x P266L (main pack fuse holder)
 * 2 x A50QS350-4 500V 350A fuse (module fuse)
 * 2 x P266C (module fuse holder)

Other possible 250V 350A fuse options (center of 250V module):
 * http://www.littelfuse.com/products/Fuses/Class+RK5/FLSR_ID/FLSR350ID.html
 * http://parts.digikey.com/1/parts/1413653-fuse-350a-250v-bolt-fwx-350a.html
 * http://www.galco.com/scripts/cgiip.exe/WA/WCat/itemdtl.r?listtype=Catalog&pnum=FRN-R350-BUSS
 * http://www.circuitprotection.ca/pdf/ClassK5_OT_OTN_OTS.pdf
 * http://swecheck.com.au/phpcode/list_products.php?product_group=5&collection=79&series=304

List of bits: -- Main.PhilipCourt - 03 Aug 2010 
 * Copper foil
 * Glue - RTV 382 intek-uk.com
 * Fibre glass mould (I have a router, will build a female plug/mould which we can use. Will cut edges to size once we know "exact" dimensions)
 * Fuse and connector designs (for connecting each layer, this is important to get right. I imagine access ports on the outer alloy casing)
 * Contactor box!
 * Physical disconnect (for easy and safe servicing) Gigavac HBD41
 * FR4 (we need the design/size so I can get costed and ordered from Jack at ECONZ) Cut FR4
 * Bikini with EVD5 BMS: