are pictures of the battery installation, including development of the battery
racks, deconstruction of the trunk and back seat, and set up of the battery
charger and regulators.
| Trunk before deconstruction.
This is pretty much what the trunk looked like at the beginning, with no
carpet and the spare tire removed.
| . . .and this is
what it looked like with the sheet metal removed! This was the first cut,
just to remove the deep drawn sheet metal that used to hold the spare tire.
| Mockup of initial
design for sheet metal box. This would have been a cleaner installation
than the welded angle iron framwork I used, but this approach would require
tools that I didn't have.
| Trunk with perimeter
frame welded in. I added some vertical supports for the frame at the back
of the car and cleaned up the surrounding metal for painting.
| Trunk battery box.
Two rows of batteries will fit - four in front, and five across the back
row. Flat stock is welded in place so that the all-thread can hold each
battery through the center.
| . . .checking with
a test battery for size:
| Verifying fit of
trunk battery box frame:
| Battery box. .
| First idea for
back seat battery box. This approach would allow for eight batteries across
the width of the car.
| Here I'm checking
to make sure I can still put the driver's seat back. It's a little tight!
After this look, I decided to modify the floor pan enough to keep all the
battery tops below the level of the trunk area shown in the background.
| This shows the
back seat area with most of the soundproofing removed:
| A close-up view
of the back seat area on the passenger side. You can see where I've marked
the area where some cutting is required to get the batteries to sit level.
| This shows the
newly welded-in material behind the driver's seat:
| And now the other
side is cut out and ready for new sheet metal to be welded in. You can see
the hand brake lines to the rear wheels and the input flange to the differential.
| This view from
the passenger door shows the new sheet metal floor for the rear battery
| Close up of the
rear battery box floor:
more pictures are on the way. Keep checking back!