Seeking Gen1 HV Battery parts ! Orange harness for Bus bar + wire sensor tabs! + nickel plated bus b

You could try autobeyours.com or Tampa Hybrids.

Which Ferndale are you, MI, WA, CA, MD or NY? A more specific location can get you better answers, if advice is location specific.

 

I think Steve at autobeyours is unlikely to have anything Gen 1. He's always had a kind of laser focus on Gen 2, has a dim opinion of Gen 3, but has also branched out into the v and the hybrid RAV4.

The very first time I was down there, he did, sort of inexplicably, have a Gen 3 out back, which I was able to scavenge some parts from, but that seems to happen rarely.

 

I would not advise that; I would replace the harness that contains the sense wires. As skinny as they are, those are high voltage connections, and weirdly enough, they are not fused or current-limited on the battery ends.

I don't think the car will care much, as long as they fit in the plastic thingies and are thick enough to carry the current.

 

You could just clean up the old ones (unless they are damaged in some way, e. g. corroded) and then nickel plate them. Or have someone nickel pate them for you.

 

Since you hot such a good deal on the car, I would take some of that savings and just purchase the setup from the dealer.
It will be in beautiful condition compare to an old gross, corroding only one.
I have tons of parts but I'm probably won't end up selling them to you. Too often folks haggle a little bit to much on price and end up being to much hassle to deal with.

I just sent probably a dozen used gen 1 and gen 2 buss bar wire frames to my favorite local scrap metal guy. Lots of good used copper, even though it is corroded

Can you resolder a broken sense wire.? Sure. But if one is broken, you will likely have more breaking soon. You'll get really good at accessing, removing, opening up, fixing, and reinstalling your pack.

I just remembered that I do have a brand new sent of sense wire frame for a gen 1 around here. It is from a dude who had me buy it for him and then backed out. So this is what I'm saying about it being too much of a hassle sometimes.

I forget, where are you located?

 

I agree with plating them yourself. I've looked into this and seems to be a fairly cheap alternative if you are familiar with electrolysis. You can do very cheap methods, or you can send more and get a nickel plating set of chemicals which Amazon carries. I've heard it done with simple vinegar and a few other items, but you need nickel bars or sheets, whatever you end u buying which is also sold on Amazon or hardware stores that act as the anodes which the bus bars will take on the nickel from the bars or sheets. They come in several different forms. Electrolysis is a very simple process if you have the items you need, which I had everything I needed. I think for electroplating you need a higher amount of voltage going into your set up than with electrolysis. But I always piggyback a 12v car battery with my trickle charger sometimes 2 12v batteries when I'm feeling crazy and want extreme rust gone really quick. Just something to think about. Fairly cheap and easy process.

 

I'm also 2 or 3 copper bus bars shy of reassembling my hev battery and installing it back in my car after it discharged and I've gotten all of the modules at voltage and holding and these 2-3 tiny bus bars are holding me back. So if anyone has 5 or what I actually need, please contact me as I do not have the money and won't unless I make it into this months semester. Also, I just recalled something from my reading on copper vs nickel.. Nickel is actually less of a conductor than copper so I guess the benefit with the nickel bars are corrosion resistance mostly?