Battery terminal covers

Things are slower with the new lock-down and travel restrictions. But I was able to move on with the battery terminal covers.

I'm mimicking the original Nissan ones, albeit using MDF as insulation (3D printing was too expensive) and 5mm aluminium bus bars (copper laser cutting was too expensive too).

This was the plan:

Plan with battery assembly
FreeCAD drawing with modules assembly, terminal cover and busbars. I should have seen the complete system before ordering the MDF sheets...

However, I was only working with the bus bars and terminal covers visible and I forgot to check the clearances for the MDF sheet :D
This will not fit between the two long metal bars as is. Nothing a small saw and elbow grease won't fix. Live and learn...

Terminal cover clearance
Ops... the two top layers need to be smaller. And I doubt the bottom one will be able to reach its place with the U-shaped profiles in place

Other than that, it's coming out alright:

MDF and aluminium bus bars
The three layers of MDF and the aluminium bus bars.

 

Mockup of bus bars and cover
Mockup of bus bars and cover

 

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