After more time fine tuning the battery spacer fitment, i’ve been able to even further optimize the structure, cutting the overall pack height down by over 1.6mm, and the width by almost 4mm from the previous revision. I’ve also managed to strategically cut material, which, due to this part being 3d printed, will actually most likely make it stronger with the way wall perimeters work. If i can get a more accurate test fit once i actually do the enclosure, i might even be able to make this pack slimmer still. As is, the maximum pack height is 41mm, but that’s with the pack following the contour of the deck, so the top at the outer edges and the bottom at the middle. If i measure it in a more accurate method of instantaneous height, it’s actually closer to 35mm of maximum pack height. Pretty impressive, considering it’s effectively a 1.5 stack battery that would otherwise not be able to fit 5P. I think with some further optimization, i should be able to cut the pack height to 34, or maybe even 33mm. This shows some serious promise for fitting packs into tight configurations, or allowing for slimmer custom fitted enclosures that can contour more closely to the deck.
Meanwhile, for the mold - Any opinions on this as a fill primer? Amazon.com: Dupli-Color DAP1689 Sandable Primer Spray Paint - White - 12 oz. Aerosol Can