Archive for January, 2009

Rear battery rack is installed

Sunday, January 18th, 2009

Some minor pounding created enough clearance for the rear rack to snugly fit into the engine compartment. Following another 914 conversion, I cut out the rubber inside the passenger compartment and drilled out the holes as I went.  MUCH easier than trying to get all the holes done right the first time.   I also got a lot more POR-15 for the exposed metal (during the various pounding episodes).  This is starting to look like a real electric car!

Rear support plates inside the passenger compartment

Rear support plates inside the passenger compartment

Rear battery rack attached to passenger compartment

Rear battery rack attached to passenger compartment

Wiring is up next.

Mid and Rear Battery Rack

Friday, January 9th, 2009

Oh my, I feel like a pale John Henry.  Making space for the middle battery rack required a LOT of pounding of metal.  Sean wanted to cut the metal, and then weld it, but I was worried about the heat on the steering column.  So for the past two weeks, I’ve taken to going out to the car, pounding on the metal for 1/2 hour and then retreating to the house.  I *think* I’ve won today, though. I do have some concern about the height of the box, but that’s for later worries.

Where the middle battery rack will go

Where the middle battery rack will go

Middle battery rack set in place

Middle battery rack set in place

Electro Auto was extremely prompt in sending the missing rear battery rack support posts.  I was VERY happy with that level of service.  However, not all is fine with the rear rack.  It doesn’t fit (of course).  I need to pound some metal in the engine compartment as well, but I’m worried about structural strength.  I’ll know more after talking to Sean.

Rear battery rack support post

Rear battery rack support post

The black pen marking on the yellow metal above the post is where the rear rack is being held up.