Battery Box Updates

The battery box is one of those things that I’ve been working on slowly for many months.

Edit, I’ve had this post in the draft stage for so long I don’t remember my initial idea of what I wanted this post to say, but I thought I’d simply post it as I’ve had many inquiry’s about how I built the box and how much room there is around the transmission.

 

It started off as a rendering:

Then turned into a real box:

Then a test fit in the car:

Check the clearances:

Test fit the sides:

Add the final panels:

Most of the aluminium panels are covered in a white protective film that will be pealed off as they are being riveted into place.

The box is insulated with 1/2″ rigid foam and has a resistive heater built into the bottom that will let me heat the battery box in the winter.  I don’t know if I’ll need it but better to have it and not need it than to need it and not have it.

I currently have a 46S3P pack of A123 20Ah pouches along with a bunch of scrap foam taking up space in what was designed to hold a 96S3P pack.

I have a temporary charger in place while I finish building the EMW 10kW charger.  It takes a long time to charge, but it lets me drive the car every day and I couldn’t be happier with the performance which will only improve as I increase the pack voltage.

The box still needs a lid and completion of the batteries and wiring however it’s at a completely usable state and a pleasure to drive.