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Are you confirming that you've actually used a grid charger on it? Have you tried grid charge/discharge cycles? My 132k mi '06 HCH battery got a reprieve with grid charging and discharging. It didn't fix everything, and I still get 1 recal per trip after sitting for at least a few hours, but it's dramatically better than the 4-5 recals per 18 mile trip I was getting each way on my daily commute.
ReVolt is local to me. I've had some interactions with Matt on my refurb efforts. He's very helpful. The person I bought my spare pack from purchased the 8Ah pack from ReVolt for his '06 HCH2, and he's very happy.
Steve
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