Re: [EVDL] battery box

[Willie2 via EV]

On 03/14/2016 10:34 AM, Rick Beebe via EV wrote:

On 03/12/2016 12:30 PM, Willie2 via EV wrote:

I'm looking for a source for a weather tight, probably fiberglass, box.
About 4'x6' and 2' high with a lift-up top.  Can anyone suggest?  Some
custom fiberglass shop?


I had www.customaluminumboxes.com make me perfectly sized welded 
aluminum boxes. I'm very impressed with the quality and as a portion 
of the 

Exactly what I was looking for.  Thanks!

I have a steel fabricator near me that makes primarily electronic 
equipment cabinets that I intended to query.  The above aluminum box 
place was so responsive, I placed an order without checking the local 
place.  I settled on .06" with .08" lid.  Under 100 pounds and under $1k 
delivered.


A little background, in case anyone is interested.  For several years, 
I've been delivering produce to grocery stores exclusively in EVs.  I 
pack my produce in used banana boxes.  My car holds about 17 boxes and, 
occasionally, I have to make two trips where one larger load would 
suffice.  For those occasions, I'm configuring a light weight trailer 
with this weather tight box that will hold 16 boxes.


I have some experience pulling ~1500 pound trailers; they seem to cost 
me at least 50% more energy, ~450 wh/m vs 250-300wh/m.  I have pulled a 
smaller lighter trailer similar to the one I'm configuring.  With the 
imiev and the light low profile trailer, the energy cost is minimal, 
difficult to notice.


Of course, the above place looks like a prime source of very nice and 
durable battery boxes.


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Re: [EVDL] battery box

[Rick Beebe via EV]

There are a couple here.

http://www.evalbum.com/4674

Let me know if you want to see more or have questions.

--Rick

On 03/14/2016 03:05 PM, Lev Lvovsky wrote:

Any chance you have pictures of the boxes that you had made?

thanks!
-lev


On Mar 14, 2016, at 8:34 AM, Rick Beebe via EV  wrote:

On 03/12/2016 12:30 PM, Willie2 via EV wrote:

I'm looking for a source for a weather tight, probably fiberglass, box.
About 4'x6' and 2' high with a lift-up top.  Can anyone suggest?  Some
custom fiberglass shop?


I had www.customaluminumboxes.com make me perfectly sized welded aluminum boxes. I'm very 
impressed with the quality and as a portion of the total cost of the conversion they were 
economical. I made them 2" larger than the cells in all directions and lined with 
them 1" of insulation. I primed them and then painted the outside with spray on 
truck bed liner. Very durable and they appear to be a factory fixture. This was my third 
winter and the batteries are as clean as when I took them out of the shipping crates.

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Re: [EVDL] battery box

[Lev Lvovsky via EV]

Any chance you have pictures of the boxes that you had made?

thanks!
-lev

> On Mar 14, 2016, at 8:34 AM, Rick Beebe via EV  wrote:
> 
> On 03/12/2016 12:30 PM, Willie2 via EV wrote:
>> I'm looking for a source for a weather tight, probably fiberglass, box.
>> About 4'x6' and 2' high with a lift-up top.  Can anyone suggest?  Some
>> custom fiberglass shop?
> 
> I had www.customaluminumboxes.com make me perfectly sized welded aluminum 
> boxes. I'm very impressed with the quality and as a portion of the total cost 
> of the conversion they were economical. I made them 2" larger than the cells 
> in all directions and lined with them 1" of insulation. I primed them and 
> then painted the outside with spray on truck bed liner. Very durable and they 
> appear to be a factory fixture. This was my third winter and the batteries 
> are as clean as when I took them out of the shipping crates.
> 
> --Rick
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Re: [EVDL] battery box

[Rick Beebe via EV]

On 03/12/2016 12:30 PM, Willie2 via EV wrote:

I'm looking for a source for a weather tight, probably fiberglass, box.
About 4'x6' and 2' high with a lift-up top.  Can anyone suggest?  Some
custom fiberglass shop?


I had www.customaluminumboxes.com make me perfectly sized welded 
aluminum boxes. I'm very impressed with the quality and as a portion of 
the total cost of the conversion they were economical. I made them 2" 
larger than the cells in all directions and lined with them 1" of 
insulation. I primed them and then painted the outside with spray on 
truck bed liner. Very durable and they appear to be a factory fixture. 
This was my third winter and the batteries are as clean as when I took 
them out of the shipping crates.


--Rick
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Re: [EVDL] battery box

[via EV]

> I have gathered several bed frames from garage sales to build a battery box 
> frame 

If you are going to weld, do NOT use bed frames! The metal has a special 
treatment that makes it more like spring steel. It is very difficult to drill 
and, if you weld it, the welds will eventually crack due to vibration. A friend 
told me this years ago but I used it anyway, only to discover he was right. Now 
I spend the money for mild steel. It's worth the added expense. 

Sent from my iPhone

> On Mar 13, 2016, at 9:08 PM, Daniel Eyk via EV  wrote:
> 
> John, how did you attach the aluminum sheets together for your box?  I also 
> need to build abattery box for my S-10 conversion. I have gathered several 
> bed frames from garage sales to build a battery box frame. Would that be 
> compatible with the aluminum sheeting?   Daniel Eyk Vancouver, Wa. Electric 
> S-10 project E-15 project E8M 
> 
>On Saturday, March 12, 2016 9:51 AM, John Lussmyer via EV 
>  wrote:
> 
> 
> I used 1/8" sheet aluminum to build mine.  Much easier than fiberglass.  (and 
> you can use a coating paint to protect it if you need to.)
> 
> On Sat Mar 12 09:30:30 PST 2016 ev@lists.evdl.org said:
>> I'm looking for a source for a weather tight, probably fiberglass, box.
>> About 4'x6' and 2' high with a lift-up top.  Can anyone suggest?  Some
>> custom fiberglass shop?
> 
> 
> --
> 
> Bobcats and Cougars, oh my!  http://john.casadelgato.com/Pets
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Re: [EVDL] battery box

[John Lussmyer via EV]

On Sun Mar 13 19:08:05 PDT 2016 daniel...@yahoo.com said:
>John, how did you attach the aluminum sheets together for your box?  I also 
>need to build abattery box for my S-10 conversion. I have gathered several bed 
>frames from garage sales to build a battery box frame. Would that be 
>compatible with the aluminum sheeting?   Daniel Eyk Vancouver, Wa. Electric 
>S-10 project E-15 project E8M

Bent the sheets for some corners, welded others. 
Currently just bolted to the steel framework - which will likely cause 
corrosion eventually. (but I'm betting I'll need to build new ones for a 
different battery geometry by then anyway.)


--

Worlds only All Electric F-250 truck! 
http://john.casadelgato.com/Electric-Vehicles/1995-Ford-F-250

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Re: [EVDL] battery box

[Michael Ross via EV]

Assuming you mean, can you put steel up against aluminum? I say no problem
but try to keep them dry, including no condensed moisture.  If you think
they will get moisture between them the consider something to electrically
insulate them from each other.  Could be rubber washers, gasket material.
roofing membrane (EPDM rubber) stuff like that.   Consider SS fasteners
like pop rivets or bolts and nuts.  You might work out an adhesive bond
with insulating spacers.  I wouldn't go with paint or powdercoat as they
might abrade away.

I would not do it this way though, I would use aluminum tubing or angle and
weld it to aluminum sheet. 1/8" sounds excessive.  Maybe 13 or 14 Gauge.  a
single 20 foot stick of tubing might go a long way.

On Sun, Mar 13, 2016 at 10:08 PM, Daniel Eyk via EV 
wrote:

> John, how did you attach the aluminum sheets together for your box?  I
> also need to build abattery box for my S-10 conversion. I have gathered
> several bed frames from garage sales to build a battery box frame. Would
> that be compatible with the aluminum sheeting?   Daniel Eyk Vancouver, Wa.
> Electric S-10 project E-15 project E8M
>
> On Saturday, March 12, 2016 9:51 AM, John Lussmyer via EV <
> ev@lists.evdl.org> wrote:
>
>
>  I used 1/8" sheet aluminum to build mine.  Much easier than fiberglass.
> (and you can use a coating paint to protect it if you need to.)
>
> On Sat Mar 12 09:30:30 PST 2016 ev@lists.evdl.org said:
> >I'm looking for a source for a weather tight, probably fiberglass, box.
> >About 4'x6' and 2' high with a lift-up top.  Can anyone suggest?  Some
> >custom fiberglass shop?
>
>
> --
>
> Bobcats and Cougars, oh my!  http://john.casadelgato.com/Pets
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-- 
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Michael E. Ross
(919) 585-6737 Land
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Re: [EVDL] battery box

[Daniel Eyk via EV]

John, how did you attach the aluminum sheets together for your box?  I also 
need to build abattery box for my S-10 conversion. I have gathered several bed 
frames from garage sales to build a battery box frame. Would that be compatible 
with the aluminum sheeting?   Daniel Eyk Vancouver, Wa. Electric S-10 project 
E-15 project E8M 

On Saturday, March 12, 2016 9:51 AM, John Lussmyer via EV 
 wrote:
 

 I used 1/8" sheet aluminum to build mine.  Much easier than fiberglass.  (and 
you can use a coating paint to protect it if you need to.)

On Sat Mar 12 09:30:30 PST 2016 ev@lists.evdl.org said:
>I'm looking for a source for a weather tight, probably fiberglass, box.
>About 4'x6' and 2' high with a lift-up top.  Can anyone suggest?  Some
>custom fiberglass shop?


--

Bobcats and Cougars, oh my!  http://john.casadelgato.com/Pets
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Re: [EVDL] battery box

[Lee Hart via EV]

Willie2 wrote:

I'm looking for a source for a weather tight, probably fiberglass, box.
About 4'x6' and 2' high with a lift-up top.  Can anyone suggest?  Some
custom fiberglass shop?


Chris Tromley via EV wrote:

What you're attempting to do is pretty simple, so just about
any fiberglass shop could do it. Expect it to be expensive.
That's because it's time consuming. It's not hard. In fact, it's a simple
enough project for someone who's never worked with fiberglass before.


I second this notion. I've made fiberglass battery boxes before as 
first-time projects, and they turned out well. Here's how I did it:


I live where there are winters, and wanted to keep the batteries warm 
without excessive heating costs. So I bought a 4' x 8' x 1" thick 
styrafoam sheet from Home Depot.


Make a test box out of scrap corrugated cardboard around your batteries. 
This box establishes the necessary INSIDE size of your battery box, and 
acts as a temporary spacer to be sure you can slide your batteries in 
and out of the final box.


Make a styrafoam box that fits OUTSIDE this cardboard box. This will be 
the core of your final box.


If you want strength, get a woven fiberglass CLOTH. If mechanical 
strength is less important than cost, get fiberglass MAT (random 
pattern). In either case, get enough to cover the styrafoam box inside 
and outside with two layers.


I recommend West System Epoxy resin. Compared to the usual cheap 
polyester, epoxies are stronger, easier to use, don't smell, aren't 
nearly as toxic, and won't attack the styrafoam, Here's a beginner's kit:


http://www.jamestowndistributors.com/userportal/show_product.do?pid=3842=email022916

Paint the outside of the box with the mixed epoxy resin. Press the cloth 
into place. When it's most (but not all) of the way cured, add a second 
layer of cloth and resin.


Once it's cured, remove the box from your cardboard box mold. Remove and 
discard the cardboard box. Repeat the process to build an inner 
fiberglass box. This isn't strictly necessary, but makes the box 
considerably stronger and more rigid, and provides a nice solid surface 
so the styrafoam won't get torn up.


--
Knowledge is better than belief. Belief is when someone else does
your thinking.  -- anonymous
--
Lee Hart, 814 8th Ave N, Sartell MN 56377, www.sunrise-ev.com
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Re: [EVDL] battery box

[Chris Tromley via EV]

On Sat, Mar 12, 2016 at 12:30 PM, Willie2 via EV  wrote:

> I'm looking for a source for a weather tight, probably fiberglass, box.
> About 4'x6' and 2' high with a lift-up top.  Can anyone suggest?  Some
> custom fiberglass shop?


​The chances that you'd find something really suitable to your application
are small.  What you're attempting to do is pretty simple, so just about
any fiberglass shop could do it.
​  Expect it to be expensive.

That's because it's time consuming.  It's not hard.  In fact, it's a simple
enough project for someone who's never worked with fiberglass before.  If
you understand how papier mache works you pretty much understand
fiberglass.  Just transfer that concept to different materials.  You can
make a mold out of plywood, styrofoam, whatever.  (Give the sides some
draft.)  Same for the lid.  Since finding exactly what you need ready-made
is unlikely, devote some time to designing it as you want it.

Best of luck,
Chris
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Re: [EVDL] battery box

[brucedp5 via EV]

Summary: Willie wants a 4'x6'x2' battery box preferring fabricated near
Austin-TX

Here are some links I found to explore:

https://www.google.com/search?q=fabrication+box+austin+tx

http://www.cantexinc.com/Products/NM_Fittings_Accessories/Junction_Box/Cover.php

https://www.google.com/search?q=fiberglass+box+4%27x6%27x2%27

https://www.google.com/#q=metal+box+4%27x6%27+x+2%27

https://www.grainger.com/category/electrical-enclosures/enclosures-and-accessories/wire-cable-and-carrier-systems/electrical/ecatalog/N-qrt

http://www.ebay.com/sch/i.html?_from=R40&_trksid=p2053587.m570.l1313.TR0.TRC0.H0.Xfabrication+battery+box.TRS0&_nkw=fabrication+battery+box&_sacat=0

https://www.google.com/#q=fabrication+fiberglass+box

https://www.google.com/#q=metal+fiberglass+box

https://www.google.com/#q=fabrication+fiberglass+box+austin+tx

https://www.google.com/#q=fabrication+box+austin+tx



-
Willie: >I'm looking for a source for a weather tight, probably fiberglass,
box. About 4'x6' and 2' high with a lift-up top.  Can anyone suggest?  Some
custom fiberglass shop?
-




For EVLN EV-newswire posts use: 
http://evdl.org/evln/


{brucedp.150m.com}

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Re: [EVDL] battery box

[Roland via EV]

   
Hello Willie, 

 

My battery box was made out of fiberglass. It held 90 large 20 inch high 300 ah 
Exide Tuder 2.2 cobalt cells 20 inches high that weigh 

about 30 lbs each. The bottom was 1/2 thick which was only supported by the two 
frame rails with two fiberglass support beams.  

Non metallic structure made it non conductance which made it electrical 
isolated from the metal body.  

 

All electrical components, motor controller, battery charger, and chassis boxes 
are all place in and on non-conductive surfaces. 

 

There are two ways to construct these boxes.  One is to make a reverse mode of 
the battery box using plywood and covering it with a 

vinyl floor covering.  Either you or a fiberglass company will than spray a 
mode release on the vinyl, spray on a gel coat and than lay up 

fiberglass cloth starting with a very fine material on the first layer and 
ending up with a heavy grid pattern on the last layer ending up

with a 1/4 inch wall thickness.  I had support angles glass on the outside 
bottom edge that was 1/4 thick that allow me to bolt the 

battery box to the bed of the pickup through into the frame rails. 

 

After the fiberglass cures, than you can have the inside surface spray with a 
two part hot mix of porcelain epoxy coating which is a very 

hard surface. 

 

The other way, is to purchase the fiberglass sheets yourself from the 
fiberglass company that are can be epoxy coating.  I have use this 

method to make a battery box that is only 12 inches high by 43 x 54 inches that 
fit in the pickup box between the wheel well housing.  Install equipment box 12 
inches high by 16  x 60 inches that  houses the battery charger, contactors, 
circuit breaker chassis, and fuses. 

 

The fiberglass company can supplied all the material to attach the sheets 
together and show you how to do it. 

 

The last method is to use aluminum sheeting which I would use if I was to 
construct a car which I would make out of aluminum.  

The aluminum support structure should be not less than 0.08 inch or we call 80 
thousands.  To just to make the box, lay out a pattern for a 

sheet metal cutting pattern.  The sheet should have flange about one inch that 
is bent 90 degrees which allows the side sheets to fasten to

by either rivets or welding if you have the machine to do this.  The side 
sheets should also have a 90 degree flange on one end, so it can 

be fasten to the next side sheet.  

 

Also the top edge of the side sheets should have a 90 degree flange for a cover 
to lay on.  You may have to put a mid cross panel about midway

in the box to support the sides if require.  

 

Roland 

 

 


- Original Message - 

From: Willie2 via EV 

To: Electric Vehicle Discussion List 

Sent: Saturday, March 12, 2016 10:30 AM

Subject: [EVDL] battery box



I'm looking for a source for a weather tight, probably fiberglass, box.  
About 4'x6' and 2' high with a lift-up top.  Can anyone suggest?  Some 
custom fiberglass shop?
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