The upper and lower groups are wired with the output line, however, I'm leaving the connection from cell 9 to 10 off until the fitting is finished. The drop in fit was tight but the separations and clearance was as expected. The next was the connecting of the BMS lines #0 and #15 to the the output wire. I've never had to crimp in wires as small as these and so, it was slow going and I've only done two so far to check the length to the BMS socket. Comparing it twice or more with the charts, I managed to make the first two BMS wires to the pins connector.
I estimated the amount of wire needed at the plug end and a tiny bit extra by the time I get to the 26 pin connector and that comes close to 11 inches. That means I may run out of wire if I maintain the equal length rule. However, the routing and sticking down the wire will be the slowest detail and just the first two wires was twenty minutes of fussing with directions and clearance.
The thermistors have there own long wires which makes eight wires I don't have to worry about and will save for last (T1, T2, T3, T4).
So it works out as two wires for the start and finish (B0 and B15), eight wires for the thermistors (T1-T4), and the remaining BMS wires wires will be from B1 to B14. Two pins are not used for a total of 24 pins to populate.
The wire I selected was a "nothing special" 22 gauge wire with a silicone jacket. It looks slim enough to fit under the final layer to cover the entire battery project. The pins are listed .3 millimeters and the crimp tool I purchased for securing the wire is listed for sizes from 20 to 32 gauge.
The pins have two positions that get the pinch down. The connector part accepts around 3.5 mm of wire the wire jacket crimp is a long prong and about 2 mm . The more tricky part is lining all this up on the tool to properly crimp and the need to test the connection prior to finalizing the insertion into the plug. I can see where the crimp might be too aggressive and actually cut the fine copper wires. The 22 gauge is the overall bundle, but the strands are very likely about 32 gauge.
