When
we sit down and count exactly where we can fit our batteries, we
decide it would be better to add a front battery box than triple
stack batteries inside the driver compartment. This will keep the
vertical center of gravity lower. We measure the area in the front
and design a battery box.
This
time we use 1 by 2 inch rectangular tubing. The 2.5 inch diameter
batteries will require a higher battery cover but this will allow
us to fit the battery box easily. The shape is a basic rectangle.
We cut the tubing at 45 degrees and lay the shape out on the welding
table.
First
we tack weld the corners. Then finish the welds. It is important
to use clamps to hold the pieces in place. It also helps to weld
a little and then move to a different section. Too much heat and
there will be too much warpage.
When
the basic rectangle is done, we add two vertical beams to help secure
the box to the car.
The
end result looks like this. The frame weights 12.5 lbs.
It
looks better with some paint. Note the tape covering surfaces that
get welded to the car.
The
front battery box fits in front of the cross member and the lead edge
goes beneath the radiator.
We
use straight edges to extend the flat bottom from the center of the
car. This gives us the mark for what height to put the battery box.
We use clamps and shims to hold it for welding. We weld the rear vertical
bars to the car.
The
front of the battery box gets welded to the chassis in two three inch
spots.
