Battery Box building
- Richo
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Battery Box building
So I'm looking to build my battery box soon.
I can get all the parts made to size, Aluminum frame + panels, if required.
But the actual frame and panels will need to be welded together.
Can anyone suggest someone in the Perth metro who would want/can do this?
Also now is the time to put your 2c worth in the overall design.
Either it will be a simple rectangular box shape if the batteries all fit or a short T-Shape like the Volt.
Polycarb inner liner.
I can get all the parts made to size, Aluminum frame + panels, if required.
But the actual frame and panels will need to be welded together.
Can anyone suggest someone in the Perth metro who would want/can do this?
Also now is the time to put your 2c worth in the overall design.
Either it will be a simple rectangular box shape if the batteries all fit or a short T-Shape like the Volt.
Polycarb inner liner.
So the short answer is NO but the long answer is YES.
Help prevent road rage - get outta my way!
Help prevent road rage - get outta my way!
- jonescg
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Re: Battery Box building
Richo - how big? Like 1400 mm long sort of thing?
AEVA National President, WA branch director.
- Richo
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Re: Battery Box building
Well it's most of the width of the car.
It's where the fuel tank used to sit but now wider as the exhaust system is removed.
I guess around 1400 wide, 300 tall, 400 long.
It's where the fuel tank used to sit but now wider as the exhaust system is removed.
I guess around 1400 wide, 300 tall, 400 long.
So the short answer is NO but the long answer is YES.
Help prevent road rage - get outta my way!
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- Richo
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Re: Battery Box building
I was thinking of 1" RHS ali frame all welded together then ali checker plate on the outside except the top.
Then the thickness is filled with something, fire proof, such as rockwool. Or EVA if I cant be bothered.
The inner is then lined with a polcarb box and the top has a sheet of polycarb.
Then the thickness is filled with something, fire proof, such as rockwool. Or EVA if I cant be bothered.
The inner is then lined with a polcarb box and the top has a sheet of polycarb.
So the short answer is NO but the long answer is YES.
Help prevent road rage - get outta my way!
Help prevent road rage - get outta my way!
- Richo
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Re: Battery Box building
$417 from superchunk auto 1400L x 515W x 480H is too big...
http://www.supercheapauto.com.au/Produc ... om=1021424
http://www.supercheapauto.com.au/Produc ... om=1021424
So the short answer is NO but the long answer is YES.
Help prevent road rage - get outta my way!
Help prevent road rage - get outta my way!
- Richo
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Re: Battery Box building
Well it's not even that big.
900W x 250H x 350D from a quick measure.
This will only hold about HALF my pack.
Looking at the original weight distribution I will have to put the other half in the engine bay anyway to get it back near 50/50.
So the short answer is NO but the long answer is YES.
Help prevent road rage - get outta my way!
Help prevent road rage - get outta my way!
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Re: Battery Box building
I'll be making some battery boxes soon too.
Both these fuel tanks will be replaced with boxes that hold 12 x CALB 180 cells , and I'll need another box holding 21 cells under the bonnet .
Constructing a box & lid is one thing, but I assumed the cells all need to be clamped down somehow, this is the tricky bit. None of the many battery box images across the internet seem to have such clamping arrangments. Are such clamps required or not ??
Both these fuel tanks will be replaced with boxes that hold 12 x CALB 180 cells , and I'll need another box holding 21 cells under the bonnet .
Constructing a box & lid is one thing, but I assumed the cells all need to be clamped down somehow, this is the tricky bit. None of the many battery box images across the internet seem to have such clamping arrangments. Are such clamps required or not ??
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Re: Battery Box building
Also what about making battery boxes from Angle & flat plate , then linking with Alloy sheet + some internal insulation. ??
Im thinking same as in this old blog http://adventure-ev.com/?p=386
Im thinking same as in this old blog http://adventure-ev.com/?p=386
- Richo
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Re: Battery Box building
Yeah I'm thinking that RHS with an outer plate and inner polycarb liner is over the top.
Plus it takes up a lot of space.
Also the internal gap, which I was thinking of putting rockwool etc would make the box flex with 80kg of battery pushing it around corners.
Angle and flat plate could work.
On the top I would have the angle going out for a mounting flange.
Plus it takes up a lot of space.
Also the internal gap, which I was thinking of putting rockwool etc would make the box flex with 80kg of battery pushing it around corners.
Angle and flat plate could work.
On the top I would have the angle going out for a mounting flange.
So the short answer is NO but the long answer is YES.
Help prevent road rage - get outta my way!
Help prevent road rage - get outta my way!
- Richo
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Re: Battery Box building
The prismatics usually need to be held tight together to prevent from swelling during charge/discharge.
The ones I have seen have used the ratchet straps like for trailers.
Luckily I am using the Leaf cells which have 4 mounting holes that have a rod put through to pull them tight and lock them in place.
So the short answer is NO but the long answer is YES.
Help prevent road rage - get outta my way!
Help prevent road rage - get outta my way!
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Re: Battery Box building
Ahh Thanks - ratchet straps - I can do that.
- Richo
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Re: Battery Box building
I guess the tried and tested way is best.
This is from Zeva's RX-7
http://www.zeva.com.au/Projects/RX7/?se ... tteryPacks
Ali box, flanged top, polycarb inner, polycarb top and external mounting struts.
Still leaves me with the problem of an ali welder.
This is from Zeva's RX-7
http://www.zeva.com.au/Projects/RX7/?se ... tteryPacks
Ali box, flanged top, polycarb inner, polycarb top and external mounting struts.
Still leaves me with the problem of an ali welder.
So the short answer is NO but the long answer is YES.
Help prevent road rage - get outta my way!
Help prevent road rage - get outta my way!
- jonescg
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Re: Battery Box building
I reckon this will work pretty well with the Leaf modules. However if you can, try and squeeze them in so there's good contact all the way out to the sides of the enclosure. Then it should be able to soak any heat away. The polycarb lining will limit how effective this is, but you will need something there for electrical isolation too.
AEVA National President, WA branch director.
- Richo
- Senior Member
- Posts: 3737
- Joined: Mon, 16 Jun 2008, 00:19
- Real Name: Richard
- Location: Perth, WA
Re: Battery Box building
Worst case I'd be pulling 3C for 10secs.
Mostly would be under 0.5C.
I'd be surprised if heat would be an issue in this case.
It's not a performance car - just a general runner.
You know all show - no go
The polycarb wont add much so I'll keep it thin like 1.5mm.
The BMS has a temp sensor on each cell so I'll know if it goes north so to speak...
I don't know if there are any other materials that would be better.
You know good thermal and good electrical isolator.
The cells will be packed in tight except for the tops due to the BMS, cell interconnects and power cabling to first and last cell.
I was thinking of making a wooden mock-up first just in case there is some obvious problem once mounted in the car.
Mostly would be under 0.5C.
I'd be surprised if heat would be an issue in this case.
It's not a performance car - just a general runner.
You know all show - no go
The polycarb wont add much so I'll keep it thin like 1.5mm.
The BMS has a temp sensor on each cell so I'll know if it goes north so to speak...
I don't know if there are any other materials that would be better.
You know good thermal and good electrical isolator.
The cells will be packed in tight except for the tops due to the BMS, cell interconnects and power cabling to first and last cell.
I was thinking of making a wooden mock-up first just in case there is some obvious problem once mounted in the car.
So the short answer is NO but the long answer is YES.
Help prevent road rage - get outta my way!
Help prevent road rage - get outta my way!
Re: Battery Box building
What about a steel frame wrapped in thin moldable plastic?