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Rear battery box almost there!

A project log for DIY Electric Vehicle from Recycled Parts

Converting a car to electric drive using recycled and salvaged EV and hybrid components.

mauswerkzmauswerkz 04/11/2016 at 04:500 Comments

More progress on the rear battery installation this week. All the aluminum metalwork in the rear is done! All that's left is to put the skins on the lower battery boxes, seal it up, prime and paint. Then the batteries can finally start going in and getting bolted down in their final homes (in the back at least). Here's a photo of the rear battery support/clamping structure completed (sans batteries). I had the upper battery installed with this at one point and it's very secure. The straps bolt down along the rear edge, wrap over the top of the battery, then get cinched down by 4 bolts along the forward edge. The lower batteries are held in place by the double "A-frame" structure in between. All very tidy.

Under the car, the pass-throughs for the coolant to the rear battery and the high voltage cables has been cut and fitted. The coolant hoses pass through rubber grommets and the HV cables pass through glands. There will be nipples coming off the main tubes at an angle to meet the hoses. Inside the car, the hoses will be split 3 ways, run through the three batteries, then rejoin before passing through the sheet metal to the return pipe. There will be a service disconnect mounted to this box as well. BMS communications will be routed inside the car as it's all low-voltage.

The goal for next weekend is to get the battery boxes skinned and painted, maybe some of the work under the car routing the coolant and HV cabling. The batteries will finally be installed the weekend following that.

The goal right now is to have the car running before its registration is due in July. It feels like we're on track to hit that goal, if things keep progressing as they have been.

Bonus photo from under the car, looking forward. Still lots of stuff to pin in place.

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