Ok ... so here's an update ... not good news, although it is progress!
The packs work, however, they take too long to heat. They take maybe 30-40% longer to heat up then the stock pack. I made up 3 packs: 1st wasn't done great, wires were too long, used an LG HG2. Also made one with the Sony VTC6. Also made one with the stock Panasonic 18650PF.
The 18650PF takes 30-40% longer to heat then the stock 18650PF ... so ...
1. Connector - took apart the stock one to check, and 100% guaranteed the one I have to replace is identical. If my problem was with the crimp then it wouldn't be the same problem on both packs. The crimps also seem nice and strong (I can't pull them apart even if I try)
2. Battery - I've tried various batteries including an identical. The tabs are thicker on the stock battery, but don't think that would be it (I'd need to swap the wire harness from the original to be sure)
3. Wire - this is where I think the problem is ... although I think I have something equivalent, perhaps it's not quite good enough. I'm already over gauge for the connectors (connector supports max 22awg and I used 20awg which
looks to be the same as the stock but feels a little more light duty ... this is a top quality silver plated copper wire as well)
So I think the logical target is the wires ... see if it's possible to go to a small 18awg? Maybe a different strand count for the 20awg?
Here's a picture of the stock battery pack and the homemade one. (been looking some more and think I just need the
right 18awg wire)
Edit: Here's the perfect wire I think ($20 in shipping + $5 for 10' of wire)
http://ca.mouser.com/Search/Product...irtualkey65010000virtualkey650-FLHTC0311-18-9