Nodge68 said:
I like that. Very professional looking, and it gives a bit of a sump for the water should it get in there. ;)
Click to expand...
Perfect from far but.......😝 and yes that had occurred to me too, I was thinking to use something like an aircon rubber drip pipe to let water out if it's an issue.

I spent more time today cleaning up various bits for painting and applied seam sealer plus another coat of red oxide to the inside of fuel tank box, then cleared away a load of junk and started disconnecting and removing the rear battery boxes from the test mule.
Because I need to replace four small modules with two large ones in the boot box I'll need to make some new holes to secure them. I'll also need to decide how to bolt the box down using the four tie down bolt holes. They are only M8 so I'll need to think of a way to reinforce the area. I really don't fancy having 130kg of battery box ripping through four m8 bolts and bouncing around the car if I'm unlucky enough to have an accident.
Ironically if the DVLA would allow drilling holes or welding to the monocoque I could make it much safer. :rolleyes:
 
Alibro said:
I was thinking to use something like an aircon rubber drip pipe to let water out if it's an issue.
Click to expand...
Or a scuttle drain valve from a Fiat 500, which is a plug with a conical tube to let water out, but prevents it from splashing in.
 
Nodge68 said:
Or a scuttle drain valve from a Fiat 500, which is a plug with a conical tube to let water out, but prevents it from splashing in.
Click to expand...
Actually on thinking about it I might just lay a bead of silicon around the top edge of the fish tank to stop water getting into it. A 3mm or 4mm bead should be enough to keep it out. ;) That way I don't need to drill any holes in the precious monocoque.
 
Alibro said:
Actually on thinking about it I might just lay a bead of silicon around the top edge of the fish tank to stop water getting into it. A 3mm or 4mm bead should be enough to keep it out. ;) That way I don't need to drill any holes in the precious monocoque.
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Not sure the fish tank could be described as structurally critical.

If so, we've all been driving around in death traps all these years :eek:
 
GrumpyGel said:
Not sure the fish tank could be described as structurally critical.

If so, we've all been driving around in death traps all these years :eek:
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I guess if you follow DVLA logic the subframes are not structural as they are only bolted to the chassis but the fish tank is because it's welded to it. :oops:
 
Alibro said:
I guess if you follow DVLA logic the subframes are not structural as they are only bolted to the chassis but the fish tank is because it's welded to it. :oops:
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From memory, the DVLA only consider structural members, structural attachment points and 30cm around them to be of significance. So the fish tank wouldn't be considered structural. It technically have a rust hole in it and the vehicle will still pass an MOT.
 
Nodge68 said:
From memory, the DVLA only consider structural members, structural attachment points and 30cm around them to be of significance. So the fish tank wouldn't be considered structural. It technically have a rust hole in it and the vehicle will still pass an MOT.
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I know of a guy who cut a hole in the boot of his car while converting it and had all sorts of problems getting it past DVLA.
The problem is they don't allow the staff they already have and are qualified (MOT Testers) to make that kind of decision. It seems these decisions are made by desk bound civil servants who may be great people but will usually say no because then nobody can accuse them of allowing a dangerous car on the road. Once turned down there doesn't seem to be a method to appeal.
I should be able to avoid any such problems with my current plans as I won't need to drill or cut anything. ;)
 
Today I got the last of the batteries out of the test mule along with cables, inverter, charger and various mounting brackets, frames etc. Only the motor and gearbox to remove now but I'll leave them where they are until the front battery frame is adjusted to avoid any drilling. :rolleyes:
I also adjusted the boot box to take two large modules instead of four small ones (the small ones are going into the fish tank) and gave it a coat of red oxide. I forgot to mark and drill for the four securing bolts but will do that before giving it a top coat. 😝

I also had a delivery of new Rustoleum paint today.

IMG_20230513_114351830_HDR.jpg


It's 2.5L satin black this time so there is a contrast between the battery boxes and the frames and brackets which will be gloss.
I'm also hoping the satin black dries a bit quicker than the gloss as it can take three or four days for the gloss to dry.
 
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I think maybe for the first time I installed batteries that will not have to be removed again. :D
So I started this morning before 8am which is very unusual for me but I wanted to get some work done before having to pick up the grannies for dinner.
As mentioned last time I'd painted the boot battery boxes so after drilling the box for the tie down bolt holes I used a large socket and a M12 bolt to indent the holes. This was so the heads of the bolts wouldn't foul the bottom of the batteries.

IMG_20230514_123214768.jpg


The spray paint was to mark the position of the riv nuts as a little gentle persuasion with a ball peen/pein hammer was required on the boot floor to make room for them. Each rivnut sticks out around 10mm below the box.
I refitted the boot carpet after cutting the bottom out of the fishbowl and refitted the fishbowl batteries. This is the bit I hope to leave in place as I have no intention of painting the cradle black. They still need connecting but I should be able to do that in situ.

IMG_20230514_123914438.jpg


I then trial fitted the main box and all looks good.

IMG_20230514_123249548.jpg

IMG_20230514_123415518.jpg


Bolting the main box down to the carpet makes it sit very nicely and should help with vibration. It has been removed again and painted with the satin black along with a few other bits so when dry I can start to button up the rear of the car.
 
Every time I look at the lid of this box I think I should remake it from a single sheet, then I look at my last sheet of steel and think I might need that for something more important and move on. :oops:
I could grind it back some more but I don't want to weld it again and I want to maintain the strength. At some stage it will be covered with carpet or some such so the ugliness of the terrible welding will not always be on display. 😜
 
Alibro said:
Every time I look at the lid of this box I think I should remake it from a single sheet, then I look at my last sheet of steel and think I might need that for something more important and move on. :oops:
I could grind it back some more but I don't want to weld it again and I want to maintain the strength. At some stage it will be covered with carpet or some such so the ugliness of the terrible welding will not always be on display. 😜
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It'll look fine once there's a nice coating of black paint on it. ;)
 
Alibro said:
Every time I look at the lid of this box I think I should remake it from a single sheet, then I look at my last sheet of steel and think I might need that for something more important and move on. :oops:
I could grind it back some more but I don't want to weld it again and I want to maintain the strength. At some stage it will be covered with carpet or some such so the ugliness of the terrible welding will not always be on display. 😜
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Focus man... Slap!

I'm really impressed with the quality of your work, but, I'm sure you would say that the priority is to get it street legal. The lid functions fine, you can come back to it if need be - and I to bet you won't need to.

Erm, does the back door close? 😰
 
GrumpyGel said:
Focus man... Slap!

I'm really impressed with the quality of your work, but, I'm sure you would say that the priority is to get it street legal. The lid functions fine, you can come back to it if need be - and I to bet you won't need to.

Erm, does the back door close? 😰
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Yip! :)


So long as the door card is removed. o_O
I'm hoping removing the pocket will give enough room for the door card but if not then plan B.... ;)
 
Alibro said:
Yip! :)


So long as the door card is removed. o_O
I'm hoping removing the pocket will give enough room for the door card but if not then plan B.... ;)
Click to expand...
I'm guessing cutting a chunk out of the battery box to allow space for the door pocket isn't an option then.? o_O
 
I used the satin paint on the large boot box on Sunday

IMG_20230515_224319294.jpg

IMG_20230515_224527051.jpg


Not completely sold on it if I'm honest but it does seem to dry quicker which is great.
I spent most of the day editing a new video so will be posting it tomorrow after a dump run and dog walk.
Being semi retired is great. :D
 
Alibro said:
I used the satin paint on the large boot box on Sunday

View attachment 288359
View attachment 288358

Not completely sold on it if I'm honest but it does seem to dry quicker which is great.
I spent most of the day editing a new video so will be posting it tomorrow after a dump run and dog walk.
Being semi retired is great. :D
Click to expand...
We live almost identical lives.

I froze my nuts off on a crispy heavy frost morning walk with the dog and, later in the day, had to run for a dump o_O
 
Alibro said:
I used the satin paint on the large boot box on Sunday

View attachment 288359
View attachment 288358

Not completely sold on it if I'm honest but it does seem to dry quicker which is great.
I spent most of the day editing a new video so will be posting it tomorrow after a dump run and dog walk.
Being semi retired is great. :D
Click to expand...

GrumpyGel said:
We live almost identical lives.

I froze my nuts off on a crispy heavy frost morning walk with the dog and, later in the day, had to run for a dump o_O
Click to expand...
Since changing my job 18 months ago (has it been that long) and shedding 8 hours a week in the process, it feels like I'm sort of semi retired too. Although strangely I don't seem to have much spare time. :confused:
 
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