2007 Prius Hybrid Pack Rebuild

I'm in the middle of cycling through my pack and have a question about the rebuilding process. I've found two options that people have done but I'm not sure which one is better.

Example 1 : Pair two modules with the same capacity together and put the highest blocks in the middle
Example 2 : Pair a weak and strong module together so the block capacity is the same throughout the pack and put the same cap blocks in the middle

Some extra info about the rebuild: About half the pack is bad (<3000). Bad luck on my part as I've seen other rebuilds only replace ~5-7 modules. OEM packs ~$2.8k and reconditions are $7-800 in my area. I probably should have went with a recondition if I knew they were using good modules (>5000) but I didn't know much before starting the rebuild.

 

I'm using a cq3 charger. From all the videos/posts about rebuilding, I was hoping that my cells would be 5000+ but only 3 hit that number. I've decided to rebuild the pack with any modules that hit 4k+. I haven't finished cycling all my modules yet but it doesn't look great.

So back to the rebuilding, I can either arrange the modules so the end blocks are ~8k and the middle will be ~10k or I can pair weak/strong to make each block around ~9k capacity.

 

Thanks for the input. Each block is made up of 2 modules. The 8-10k are the discharge number from both modules. The 7500mah you're referring to is probably the charge. I have my charger set to 7200 as a safety precaution but will bump it up to 7700 then 8200 if needed.

 

Update: I have about 10 that made the 4k+ mark and 8 that are in the maybe (3k). I've only run 3 cycles as I've found that running more doesn't always produce results and it takes time. I will run more cycles once I finish the pack.

I've decided to pair the strongest modules together and place them in the middle.