Well, the cell design I was going to use is based off the design of optima batteries. These batteries use thin and flexible plates which are insulated from each other by a fiberglass cloth. The electrolyte can pass through the fiberglass but the two electrodes cannot touch, yet they remain very close together.
There are a number of companies that make nickel "foil" with thicknesses ranging from as little as .001" to .1"
The plan was to wrap the nickel foil at a thickness of .009" between two layers of fiberglass and a layer of thin steel sheeting on top(hopefully also around .01" but at least as pliable). These layers will be rolled and leads attached to the beginning of one and the end of another.
At the proposed thickness, the nickel will be totally saturated by electrons on both sides of the foil, thereby resulting in the maximum possible energy density. The thinness of the fiberglass insulator should hopefully help maximize performance of the batteries since the electrons will have only a short distance to travel through the electrolyte.
I hope to build a prototype cell this winter. Since the foil is only sold in large quantities, I have to put the project on the backburner until it is more practical to spend the money on the components(according to my timeline of projects I have to complete for my off-grid cabin). I hope to achieve 1kWh cells in a relatively small dimension. Failing that, my goal is to achieve at least a 1 KWh 12volt bank for less than $500 in materials. If it works out, I'll post a little article or maybe a youtube video on it so folks can build their own cells at home.
I chose NiFe batteries over lead acid batteries because I want and need batteries that are not damaged by being left uncharged for long periods of time. My cabin will be unattended for months at a time, and no charging of the batteries may occur. I also wanted a battery that only had to be purchased once in my lifetime. NiFe batteries, while lacking the performance of a lead acid battery, fits that bill. Its all about long term cost effectiveness and independance for me.