Battery boxes were constructed using 1 1/4″ X 1/8″ steel angle iron. Many people have suggested using 3/16″ but I found this to be difficult to work with and added unnecessary weight. Each of my batteries weigh 80lbs with a total pack weight of 960lbs. Haveing the weight distributed as near to original is very importand to maintain braking bias so I placed  batteries in the front pack with the other six in the rear.

In order to retain as much trunk space as possible the spare tire well was removed and replaced with a sunken batter tray frame. This frame was then lined with a plastic material called “CoroPlast”. This material is resistant to dirt, oil as well as battery acid. The sides of this box were then sealed to this trunk floor for a water tight seal. A cover will be made to contain the Hydrogen produced during charging.

As can be seen in the last image two conduits were ran from the front of the car to the rear to connect the two packs together forming on 144V pack. The material used was a plastic, 1 1/4″ tube, called InnerDuct. This duct is often used to run fiber optic cableing inside of buildings and it very durable. It was fastened to the bottom of the vehicle with plastic hangers using self tapping screws.

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This entry was posted on Monday, October 27th, 2008 at 8:02 pm and is filed under EVBIMMER. You can follow any responses to this entry through the RSS 2.0 feed. You can leave a response, or trackback from your own site.