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- 22:53, 17 December 2006 diff hist +128 N File:Batt Box with Bolt Down Angle.JPG Corner bracket in place and screwed down on the top. Ready to drill holes in the side and bolt down the bracket from the sides. current
- 22:51, 17 December 2006 diff hist +264 N File:Plexiglass Shield.JPG I choose to install a plexiglass 'shield' on the side of the aluminum angle iron to reduce the risk of a wire / terminal hitting the aluminum and arcing. I am not sure if that is in the official CalCars plans or not. It is held in by non-conductive nylo current
- 22:43, 17 December 2006 diff hist +81 N File:Batt Box Top 3 Angles.JPG Aluminum angle irons cut with 45 degree angles and laid on top of the battery box current
- 15:40, 15 December 2006 diff hist +1,539 PriusPlus-RawData Added Chris's Battery Box Photos
- 05:34, 15 December 2006 diff hist +88 N File:Top Battery Box With Corner Bracket.JPG Corner bracket is just sitting on the top of the battery box waiting to be screwed down. current
- 05:33, 15 December 2006 diff hist +73 N File:Top Battery Box 45 Degree Cuts.JPG The aluminum angle irons are cut with 45 degree angles so they fit snugly current
- 05:31, 15 December 2006 diff hist +80 N File:Starting on the Top of Battery Box.JPG Bottom is mostly assembled, now starting on cutting the angle irons for the top. current
- 05:29, 15 December 2006 diff hist +73 N File:2 Trays with Some Supports.JPG 2 of the trays sitting on 2 1-1/2 angle irons (others just sitting there) current
- 05:19, 15 December 2006 diff hist 0 N File:4 Finished Trays.JPG current
- 05:18, 15 December 2006 diff hist 0 N File:Finished Tray.JPG current
- 05:17, 15 December 2006 diff hist +221 N File:Screws Sticking Through Partially Assembled Tray.JPG I used extra long, self threading screws, so they stick through. I used a hacksaw first, and then a dremel with a metal cut off attachment to cut the screws at the base. Then used a grinder to grind them perfectly flat. current
- 05:14, 15 December 2006 diff hist +76 N File:Closeup of Sample Finished Corner.JPG This is just a sample I tried on a scrap pieces before doing the real thing. current
- 05:12, 15 December 2006 diff hist +241 N File:Holes drilled in aluminum.JPG Holes drilled in the aluminum. Used the dremel to drill through both angle irons in the same place, then drilled a larger hole in the top (so the screw would go through without threading and then countersunk it with a much larger drill bit. current
- 05:10, 15 December 2006 diff hist +34 N File:Tray Parts Laid Out.JPG All the parts of one tray laid out current
- 05:08, 15 December 2006 diff hist +82 N File:Dremel Drill Press.JPG This is the Dremel drill press I used to drill the small holes in the angle irons. current
- 05:06, 15 December 2006 diff hist 0 N File:Almost Finished Tray Jig.JPG current
- 05:04, 15 December 2006 diff hist +45 N File:Making Tray Jig Step 3.JPG Place wood to hold the channel irons in place current
- 05:02, 15 December 2006 diff hist +97 N File:Making Tray Jig Step 1.JPG Step one is to place wood around the outsides of the angle iron to hold the angle irons in place. current
- 05:01, 15 December 2006 diff hist +100 N File:Making Tray Jig Step 2.JPG The set together tray with batteries and wood secured in placed around the outsides to form the jig. current
- 04:58, 15 December 2006 diff hist +136 N File:Tray Ready for Jig.JPG This photo is of the tray set together on a sheet of plywood (wich will be used as a jig to hold everything in place for drilling holes. current
- 04:56, 15 December 2006 diff hist 0 N File:Tray Set Together Close Up.JPG current
- 04:55, 15 December 2006 diff hist 0 N File:Tray Set Together With Battery.JPG current
- 04:54, 15 December 2006 diff hist +70 N File:Tray Pieces.JPG These are all the aluminum pieces needed to build the 4 battery trays. current
- 04:51, 15 December 2006 diff hist 0 N File:Cutting Aluminum.JPG current