Salvaging a Smart Fortwo battery

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RonStriker

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We got a cheap Smart Fortwo battery pack for the cells inside. Anyone ever cracked one of these open? Looks like a tough nut to crack - plastic trays seem fused together and glued to metal mounting blocks. Thinking strong epoxy? Any tips on safe disassembly or alternative cell sources would be a huge help!
 
I tried to dismantle the battery pack, but it seems they designed it to stay together. The batteries were glued into the trays at both ends, making repairs difficult. So, I decided to buy a new one instead of tackling a tricky fix. LOL
 
Wow, that's a lot of work! It looks just like a Tesla pack. It'd be great if there was a way to reuse parts of it without breaking it down into individual cells. Are there any markings on the cells?
 
Whoa, that sounds like a tricky situation! But if you're set on figuring it out, I'd say maybe try giving those trays a gentle blast with a heat gun to loosen up the glue before you go prying them apart. Should make it a bit smoother and hopefully won't mess with the cells. If that doesn’t work though. maybe swapping out the cells or looking into some aftermarket options could save you a ton of hassle.

Anyway, have you thought about repurposing the pack for something else?
 
Good luck my friend! That;s probably one of the trickiest to do and the most work I've done. Try to extract them two at a time. That was the only solution I found.
 
RonStriker said:
We got a cheap Smart Fortwo battery pack for the cells inside. Anyone ever cracked one of these open? Looks like a tough nut to crack - plastic trays seem fused together and glued to metal mounting blocks. Thinking strong epoxy? Any tips on safe disassembly or alternative cell sources would be a huge help!
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Hey, just checking in! Any updates on how the disassembly is going? Can’t wait to hear how it all turned out!
 
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I thought Tesla made the first-gen Smart EV battery packs but that’s not the case. Early models had a unique setup but later versions switched to pouch cells from the Mercedes plant. It’s interesting how Mercedes took a bigger role as the tech evolved
 

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