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Battery box frame - primed. 1 1/2" x 3/16" steel angle constuction. |
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Front bed mounts. |
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Close up of bed mount (made from two pieces of angle) |
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Rear bed mounts. Not drilled until installed. |
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Frame in final color. Gold for all electric rack and component bracket mounts. |
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Front on view. |
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1/2" plywood sides. |
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Must leave gap in top of mount hole wood in order to make it easier to tighten connector later. |
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3/4" plywood bottom. |
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Bottom view of plywood bottom, which is nipped and tucked to make bottom account for welds and to fit flush with bottom of frame. |
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Bed hold down bolts removed. Next: hand prime and paint of bed until final paint job. |
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Whomp! In goes the box. It almost exactly fills half the bed. Plenty of room left for shopping/errands |
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Outside view of wiring connection point. |
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Front mount bolted in. Note: number 55 star drive needed to move the bed bolts. |
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1 1/2" Sealtite (waterproof armored flex) connector installed. |
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Outside view of connector. One on each side - right for high power wiring to front, left for instrumentation to cab |
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Batteries "dropped" into the box. 10 Trojan J185P's for the pack (120V). To balance the weight in the truck I had to move two up front. 113 pounds each - go figure. |
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Cover the parts of the pack that are not being worked on. Be VERY careful! |
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Fuse at rear in case pack or wiring to the front shorts. |
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The pack is all wired up. Yellow wires are for instrumentation and PowerCheq modules. Note 120VAC exhaust fan wiring has also been run. |
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Unseen - wooden spacers separate batteries. Note that battery retention rails have been installed. |
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Front battery rack. 3/4" x 1/8" angle. |
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Another view of front rack. |
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1/2" plywood is under batteries. |
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A bit hard to see, but unpainted battery clamp in trial fit. Had to make this twice - had first one through painting before I figured out that I blew the measurement by 1/8". Arrrgh. Note yellow heat shrink sleeving on all-thread. |