User:Cewert

Cutting the aluminum with a hacksaw

All the pieces necessary for the battery trays

All the parts from the tray laid out

Battery tray just set together

Close up of the battery tray just set together

Tray set together, ready for creating "jig"

Starting to assemble the jig

More assembling the jig

Getting the jig assembled

Mostly finished tray jig

Dremel drill press used for drilling holes in angle irons

Holes drilled in the aluminum, then countersunk

Sample corner finished (done on scrap aluminum)

Shows the self threading screws sticking out

The finished tray

All 4 finished trays laid out like they will be

Experimenting with the support angle irons

Starting on the top of the battery box

45 degree angles cut in angle irons

Corner bracket just set on the top

3 angle irons cut and just sitting on the box

Shows the Plexiglass "shield" on the inside of the angle irons

Partially assembled battery box - bolted on top, but not the sides

Inside of the corner of the battery box top

Binding posts that I choose to use. They worked, but they aren't part of the official conversion method

A completed corner, bolts in and have been ground off.

Shows the angle iron that will be used to bolt down the top

Mostly finished battery box. Still lacking the bolts in the center of the pack, holes for bolting the top down and holes in the frame

Fuses and holders

A fuse in it's holder

Bottom of the fuse holder (for DIN rail mounting)

The Kilovac EV200 contactor

Battery Box sitting on steel tube

Battery box sitting on steel tube with second tube for screw lift support

Alt mounting method: modified hanger bolted into battery box mount

Alt mounting method: Test fit of unfinished battery box top in forward location

Charger in tirewell

Welded support connected to support angle irons

Welded support connected to support angle irons

Support angle irons

Right side battery box supports

Left side battery box supports

Rubber pad under support angle irons

Entire battery box mounting supports

Electronics box being assembled

Mostly completed electronics box

Mostly completed electronics box

Installed electronics box and charger

Installed electronics box with top on

Close up of HVD1 installed

Close up of contactors installed

Left side of electronics box

Right side of electronics box

Close up of fuses in electronics box

Close up of ZiVan NG3 charger

Unstuffed control board - front

Unstuffed control board - back

Batteries being installed

More batteries

Battery box top (modified for alt. mounting)

Bolt on top of OEM battery

Removing carpeting from on top of OEM battery

Removing the upright part of the rear seat

The OEM battery exposed

Opening the OEM battery lid

Inside the OEM battery (unmodified) from rear of car

Inside the OEM battery after HV tie-in

Unmodified OEM battery low voltage wiring

Modified OEM battery low voltage wiring (for charge interlock)