RE: A123 balancing ?
We still have not solved the 3 bad packs. Were the cells soldered on the ends ? If yes. They were probably overheated and vented a small amount of the capacity. There is / was a pressure relief valve built into the LIFEPO4 cells at 1 end. I think I would take the chance of more damage to the bad packs and put the GOOD cells together into 2 good cell packs.
Were the cells soldered?