{"id":2007,"date":"2010-12-30T21:55:06","date_gmt":"2010-12-31T04:55:06","guid":{"rendered":"http:\/\/www.corbinstreehouse.com\/blog\/2010\/12\/plug-bug-rear-battery-box\/"},"modified":"2010-12-30T21:55:06","modified_gmt":"2010-12-31T04:55:06","slug":"plug-bug-rear-battery-box","status":"publish","type":"post","link":"https:\/\/www.corbinstreehouse.com\/blog\/2010\/12\/plug-bug-rear-battery-box\/","title":{"rendered":"Plug Bug: Rear Battery Box"},"content":{"rendered":"

\n

Don’t forget about the original design: http:\/\/www.corbinstreehouse.com\/blog\/2010\/12\/plug-bug-battery-box-design\/<\/a><\/p>\n

I did modify it slightly as I went along. I learned a lesson from the front box: add 1\/8″ or so to the total length to avoid it from being too tight. I started the rear box by welding up the bottom piece. I also used this piece to figure out where it would attach to the frame. I ended up using the rear seat belt mounting points and also the side seat belt mounting points; those worked out perfect!<\/p>\n

\"IMG_0364.jpg\"<\/a><\/p>\n

The box is quite large, and just barely fits into the car. I had made a cardboard version first, but I was worried it wouldn’t fit in (but it does!).<\/p>\n

Next I made the top piece — it is too pieces of angle iron welded to 1\/8″ thick flat stock on the ends:<\/p>\n

\"IMG_0369.jpg\"<\/a><\/p>\n

I had to do the ends twice; originally it was too tight (again!) and I had to move them to the outer side of the angle iron, which actually worked out better for strength.<\/p>\n

The initial trial fit seemed to indicate the whole box was like 1\/2″ too large; so, I removed 1\/4″ from two places, thinking that would be perfect. In the end, that was too tight (again!!). I could fit the cells in, but I couldn’t drop them in vertically, and I just needed a little more wiggle room.<\/p>\n

\"IMG_0397.jpg\"<\/a><\/p>\n

After a few cuts and re-welds I did a trial fit of the box in the car:<\/p>\n

\"IMG_0410.jpg\"<\/a><\/p>\n

I then used some angle iron to fill in the vertical pieces to add strength:<\/p>\n

\n\"IMG_0415.jpg\"<\/a><\/p>\n

It took me a while to get these in and straight: I had to cut the tack welds on one side and redo them in a better position (with some hammer persuasion).<\/p>\n

Finally, a trial fit in the car:<\/p>\n

\"IMG_0418.jpg\"<\/a><\/p>\n

Also notice the rear batteries; they will sit on this little mount, and be strapped to it to prevent movement in the Z axis:<\/p>\n

\"IMG_0432.jpg\"<\/a><\/p>\n

The back section ears are for mounting the lexan cover on top — they perfectly align with the battery box right in front of it. The rear set consists of 5 cells strapped together between two 1\/8″ sheets of aluminum plating:<\/p>\n

\"IMG_0379.jpg\"<\/a><\/p>\n

The rear box after painting metallic silver (that’s what I did all today!):<\/p>\n

\"IMG_0429.jpg\"<\/a><\/p>\n

Tomorrow will be a fun day; the boxes will be be installed and batteries will be slid in place!<\/p>\n","protected":false},"excerpt":{"rendered":"

Don’t forget about the original design: http:\/\/www.corbinstreehouse.com\/blog\/2010\/12\/plug-bug-battery-box-design\/ I did modify it slightly as I went along. I learned a lesson from the front box: add 1\/8″ or so to the total length to avoid it… [read more]<\/a><\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","jetpack_post_was_ever_published":false},"categories":[34],"tags":[],"class_list":["post-2007","post","type-post","status-publish","format-standard","hentry","category-electric-bug"],"jetpack_featured_media_url":"","jetpack_sharing_enabled":true,"_links":{"self":[{"href":"https:\/\/www.corbinstreehouse.com\/blog\/wp-json\/wp\/v2\/posts\/2007","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.corbinstreehouse.com\/blog\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.corbinstreehouse.com\/blog\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.corbinstreehouse.com\/blog\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.corbinstreehouse.com\/blog\/wp-json\/wp\/v2\/comments?post=2007"}],"version-history":[{"count":0,"href":"https:\/\/www.corbinstreehouse.com\/blog\/wp-json\/wp\/v2\/posts\/2007\/revisions"}],"wp:attachment":[{"href":"https:\/\/www.corbinstreehouse.com\/blog\/wp-json\/wp\/v2\/media?parent=2007"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.corbinstreehouse.com\/blog\/wp-json\/wp\/v2\/categories?post=2007"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.corbinstreehouse.com\/blog\/wp-json\/wp\/v2\/tags?post=2007"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}