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04.02.2008, 12:10 PM
How are pack temps? If they are dropping that much with ~120A current, they should be quite hot. A 4.5v drop at 120A is 540 watts! That kind of power should easily be able to be felt as heat somewhere. Granted, that's burst power, but still a heck of a lot!
If pack temps are within acceptable limits, I would start looking at contact/wire resistances. A voltage drop ANYWHERE from the battery, wires, or connectors will cause issues. An easy way to find problem areas is to feel for higher temps manually. Where it's hot means there is resistance (=v drop). So, after a run, feel various places and note higher temps.
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