SECOND BATTERY MODULE MOUNTING PREPARATION

Thursday evening I took a trip to ACE Hardware and picked up some thin steel plate, fasteners, and 12 in lengths of 1/4 in threaded rod. I had made a template of the battery module end last week and used the template to make two steel end plates. After the end plates were cut, drilled, and fitted, the strap holding the half module was loosened enough to slide the plates onto the ends and the threaded rod was inserted through the holes on each corner. Then a large clamp was used to compress the half module enough to get the nuts started on the threaded rod. There is a bit of a recess on the edges where the threaded rod comes through the end of the module, so the hardest part of getting everything bolted up was getting a 1/4 in washer behind the plates, so the plate would seat nicely on the end of the module. 

STEEL END PLATE BOLTED TO MODULE

There will be an insulated terminal bolted to the steel plate and a copper bus bar will be bent to connect the battery terminals to the terminal on the end  plate. This will be where the cables going to the rear pack will connect and a hole will be drilled between the battery terminal and the insulated terminal to connect the third module, that will be mounted in the front area where the radiator used to be mounted.

Aluminum angles will be drilled to bolt to the bottom threaded rod on the modules, then will be bolted to the deck plate that was just installed. I may put a piece of rubber sheet under the modules so they will have a little padding, instead of just sitting on the deck plate.

EXAMPLE OF ANGLE MOUNTING

Tomorrow I am going to calk and finish painting the outside of the new French Patio door I put in last weekend and will probably do some touch up painting around the inside molding but then plant on going back to ACE Hardware and picking up some more 1/4 in threaded rod to get the other half module ready. I am also going to need to order some more insulated terminals, as it seems all of the ones I had, have already been used.

It is a little exciting as the second module will allow me to drive the Fiero to work, so once the module is installed, I plan to drive the car into Columbus, OH on the weekend to test it. There is a public J1772 charger about 11 miles from home, so if it looks like I am running out of juice, I can stop there to put enough charge in the modules to get me home.

Thanks for visiting,

Randy

THE BEST LAID PLANS OF MICE AND MEN!

Work continued on the front trunk enclosure on Saturday and the cross members, wheel wall, firewall and deck plate support angles were coated with etching primer, then painted satin black. Everything was rolling along nicely and the only obstacle left was one brake line that still did not fit into the channel that had been cut in the support angle. After several attempts in straitening it out, I finally came up with a plan to clamp the bend between two blocks of wood and hopefully, when the c-clamp was tightened, the tube would straighten out enough to fit. With the clamps in place, tightening began and the tube began to bend back where I needed it to be, success was in sight! With the tube almost there, I took another couple turns, with resistance starting to increase, then there was a squirt and my hand became drenched with brake fluid. Oh well, just one turn too far. I guess it is better to snap the line now that to have it break when I am on the interstate going 70 mph, so went in the house and called a local mechanic in Kirkersville, OH. We talked for a few minutes and he agreed to put new brake lines on the car next week and then bleed the brakes after they were installed.

BRAKE LINES

DECK PLATE AND SHEET METAL FINAL PREP

With the car going to the shop next week for new brake lines, focus will turn to getting the battery pack ready. The pack will be split in half and each half pack laid flat on a plate with four pieces of all thread attaching the cells to the plate. A mount will be bolted to the fender wells on each side to bolt the module plate firmly to the car.

SECOND BATTERY MODULE

BASIC ARRANGEMENT OF NEW MODULE

Thanks for visiting,

Randy