Has anyone converted 2003-2005 Honda Civic Hybrid (5spd/AT) NiMH battery pack into 4th Generation Honda Lithium battery, similar to 48S LiBCM (5ahg offered by Greentec) with 40%CurrentHack style like they do at InsightCentral.net? Can you guys share, the procedure, parts, modifications, youtube sites, if any?

 

I've wondered whether it would be possible to rebuild the battery using off the shelf Lithium Ion Batteries.
Something like a bunch of Headway brand LifePo4 batteries, enough for a similar capacity and voltage to the original. The original battery casing could even be repurposed. Then to trick the car into thinking nothing's wrong, a microcontroller such as an Arduino, and some other electronics could be used to spoof the balance leads and temperatures the car is expecting to see.
It seems like the spoke in the wheel is the requirements for the BMS. Assuming the battery is constructed of ~50 high current batteries in series (since 180V expected / 3.6V for fully charged batteries = ~47), I believe a custom BMS would have to be built. It would require a lead to every single cell, and insane charge and discharge currents to match the power of the electric motor. I'm sure there's a more sensible way to do this, I'm just extrapolating from knowledge of solar battery systems.
I'm sure the parts at least would be cheaper than purchasing a replacement NiMH battery for 2k.

And the final step is to start selling these to recoup the several years spent for development. And if you're smart enough to design that BMS, you're probably smart enough to escape when Honda and the Federal Gov't kicks in your front door.