Battery box trial

I received the sheet metal parts for the first version of the battery box and started assembling it.

Battery box location
Proposed location for the battery box.

But first, with just the mockup of the box, I checked the location. I'm planning to take out one of the rear seats and reuse (some of) the existing holes. I choose the side right next to the filler neck, which will be used for the charging port.

Some of the battery box parts
Some of the battery box parts, namely the modules and brackets

I started assembling the pack, pushing the modules through the rods and using the end plates to squeeze them so I could bolt the brackets to the outside beams every four modules.

Battery box stack
The start of the stack.
Using the end plate to squeeze the modules
Using the end plate to squeeze the modules


Half of the stack done
Half of the stack done

I had to stop half way because I ran out of nuts! :P

Next post should be about the built box, although I still need to fabricate the bus bars. Not many shops do laser cutting on copper and it's more expensive, so I will probably stick to aluminium instead (even if I need to make it thicker).

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