Rear Battery Boxes...Beginnings

This post covers work on April 25 and 26. Before the weekend I made a trip to Harbor Freight to purchase a chop saw and a sandblaster (to be used later). You can't beat Harbor Freight for great prices on tools. I also acquired enough steel to complete the rear battery racks from a local steel contractor. My last big purchase was a welder from Craig's List. Now I just need to learn how to weld! :) Luckily my son's friend is a very good welder.

I hammered together 4 rectangular pieces of wood in the exact size of the batteries that I am going to purchase to assist in making the racks. After working the details out on graph paper, I began cutting the angle iron and flat stock for the bases of the racks. The first series of photos show the rack that will be behind the rear axle and under the truck bed. The cut pieces are laid out on the floor in the way they will be welded together. This rack will hold 8 batteries. After these pieces were cut, I moved on to the racks that will be in front of the rear axle and behind the truck cab. These will also be under the truck bed. By putting the batteries under the truck bed, I will retain the use of the bed. You never know what you may want to carry in a pickup truck.

The front left and right battery racks will hold 6 batteries apiece. They will be positioned on either side of the drive shaft. The plan is to support these racks with square steel stock running across the frame of the truck.

Still moving forward toward completion. I can't wait to drive this truck on a daily basis. More steel to cut and lots of welding in my future. Stay tuned right here for more EV conversion fun!