Large plastic Li-ion (PLI) cells (25 to 28-Ah) were fabricated for an EV application. The 28-Ah cells showed high specific energy (160 Wh/kg), high specific power (526 W/g), excellent round-trip energy efficiency $(92\%)$, and low self-discharge rate ($6\%$ in 30 days). A 25-Ah cell of an earlier design showed good cycle life of up to 750 cycles at $100\%$ DOD to $80\%$ of its initial capacity, while cycle life test of a 28-Ah cell of a later design is in progress. Preliminary safety tests were also carried out using 6-Ah cells of a similar electrode design giving very encouraging results for development of a safe hish-energy density PLI battery for EV application.