So, this got posted again I see. A few years later: the pack is still going strong and has not - so far - shown any signs of wear. I've put close to 15000 Km on it now and there is no degradation worth mentioning, though I suspect that if I do a precise capacity measurement that it would definitely show some reduced capacity. The really neat thing is that at the end of a long ride the cell groups still track to withi…
> I hope this article will inspire people to look at e-bikes as potentially commuter car replacement, to send Bosch and other e-bike technology manufacturers a message that if they won’t supply what people need that they are going to have to live with people hacking their stuff Did this ever happen?
Balancing wires and physical damage to the pack because of insufficient rigidity of the shell and a lack of shock absorbing material are the main causes of pack problems, water ingestion and bad materials / manufacturing defects are also a real problem.
The balancing wires, shell rigidity, shock absorbers and seals are all on the manufacturer, how you treat the pack and monitor it is on the user.
The worst are the pannier mounted ones, I personally think these should all be recalled and replaced. I've seen more than a few of those that had internal signs of fire damage and that must have come within a hair of thermal runaway.