Build an Electric Car: Installing the Battery Box

Since 10 of the batteries will be located in the rear section of the passenger compartment the batteries will need to be stored in a protective box. This is to prevent fumes from entering the passenger compartment when the batteries are charging and to protect occupants of the car in an accident. The box also keeps the batteries warm in cold weather. Because of the limited space in the front of the car, battery boxes were not installed.

Mounted on the side is an explosion proof brushless fan that ventilates the box when the batteries are charging. The fan is wired in series with the fan in the battery charger so when the charger is on the battery box fan is on. A marine grade ventilation bilge hose is attached to the fan and routed to the vent on the underside of the car.

The box is constructed of marine grade plywood and painted with water repellant paint. Metal banding is secured around the box so the weight of the batteries will not break the box apart in an accident.

The box is securely mounted with bolts to the frame of the car. For ease of installation the box in this conversion fits in the trunk. However, with careful planning, some cutting, and a little welding, the battery box can be sunk into the floor of the trunk to regain storage space. Before the batteries are installed, a layer of baking soda is spread on the floor of the box and the air bags in the coil springs are filled with air.

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Next step is wiring the car

January 10, 2009 · Filed Under Build an Electric Car

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