Battery boxes and racks

I've moved a few millimeters forward lately. This post will have a bunch of pictures of some test fittings of the batteries in the front battery racks and also some more shots of the hatch area of the car where the battery boxes will go. I cut a few pieces of aluminum to put under the batteries and on the ends. The ones underneath will help give a nice flat surface for the batteries to sit on since I have some bolt heads underneath the racks which stick up a bit. It will also protect the bottoms of the batteries if debris somehow gets kicked up underneath them. The end plates are there because I will be strapping the batteries together to help protect against swelling in the event of an over charge. From everything I have read, there does not seem to be a problem with swelling at this point as long as you stop the charge at around 3.6 Volts per cell average, but if a cell got out of line from the others, as far as voltage, then it could over charge and swell up. Early on, I will be checking the cells after charge and after use quite often, but after a while it will probably only be once a month or so.

Bumper rack with (8) TS 160AH batteries

Firewall rack with (8) TS 160AH batteries

Both racks loaded up

Reverse angle with Control board sitting where it will be mounted over the motor

The next set of photos is in the hatch area. I finished painting the angle iron frame that the battery boxes will be hanging from, and have put them in place for a test fitting. I spent last weekend looking at what I need as far as hardware to bolt everything in place and making a big purchase list. I will be using a bunch of 1/4-20 Stainless Steel bolts and nuts, along with Nordlock washers. I am also buying a few M6 and M8 bolts for various areas where I can use the existing mounting points on the car.

Battery box frames in place

Added interior plastic to wheel well area

Note in the above picture the black plastic interior pieces. I got these off of a CRX forum a few months ago. Someone wrecked their car and was parting it out. My interior is actually blue, but I am ok with the black in the hatch area. I am still missing the piece on the back wall that covers the tail lights, so I will have to scour the net some more. It sure beats going to the local pick-a-part every weekend.

The next big issue is to look at the 12 volt wiring diagrams for the car and start to figure out what all the connectors are that are just hanging in the engine compartment. I didn't label them when we took the engine out and am kicking my self now. I won't need most of them, but I need the starter signal and there was some creative DIY wiring for a couple items that I need to figure out and replace.

Also, a couple guys are planning on coming over on the 16th to look at my progress and give me their thoughts before I head into a full week of work on the car. I am excited about that week, because I can knock out a bunch more things on my To Do list. Hoping to do a bunch of work on the control board and the original 12 volt system in the car.