BATTERY
We begin, as all good things must, with a totally reasonable number of high capacity 2170 cells:
They’re glued up so that they can fit mostly under my feet, which trades away ~15mm of ground clearance to achieve a better sprung mass ratio for the “suspension”. If the pack avoids the center of the deck, where all the movement during flex occurs, the pack will avoid most of the vibration and provide less resistance to the wheels trying to move over bumps.
Fishhhhhhhhhhh. You know the drill.
@Evwan lent me his kweld for a couple weeks and I managed to get everything hooked up with 0.2mm nickel after an embarrassing number of test welds. The 4 center groups are conventional double stack, but the 8 groups at each end are more like a brick pack, with current zigzagging up and down (from the perspective of the brick on the left in the pic). You can see the nickel fold showing between the top and bottom halves.
Onto the enclosure. For the mold I stacked up different thicknesses of foam and wood to get the right height for the each section, and put drafts all around by carving and sanding.
After covering the deck with packing tape and a plastic bag, I glued the blocks into position and started adding layers of 3 mm foam around them for flanges and wire routing space. This stuff got a layer of fiberglass, more sanding, and five layers of mold release wax.
Fiberglass mat in a bag, not much to say.
i did think of a joke but it was pretty vacuous
Out of the bag and trimmed with some snips while the epoxy was still soft, but still needs sanding around the edges. Bedliner will hide the rest of my sins.
With the sins hidden under a glorious, rubberized coating, the battery and BMS get wired up.
