Build Session 14 (30 mins): Battery Rack Build Session 7

Tonight I cut (most of) the rear support section out of the Chevy S10 frame. This piece needs to be removed to make room for the polyurethane battery boxes that I will build in the near future. That sums up my accomplishments for this weekend as I am camping with the family at Whidbey Island.

Using the Makita with a cut-off wheel...

Support section removed...

I plan to remove the rest of this support section after completing the rear battery rack and adding additional support to the shock mounts.

Build Session 13 (1 hour): Rear Battery Rack Welding

Back from San Diego and ready to work on the truck...

I did get three of the support bars welded into the rear battery rack tonight.

Of course I wouldn't have been able to do it as fast without a little help from Tayler.


We clamped the "U" shaped pieces into place and squared and welded them to the support tubes (one side at a time).

Notice the surface rust building up already...don't worry, my POR15 chassis coat epoxy showed up last week. As soon as these battery racks are done I will prep and paint. :)


Tayler with a wire brush...I wish that I could get her to scrub the dishes this good. :)


Using the Makita wire brush to clean up my welds.


Three pieces welded in place. In my next session I will build 3 additional pieces to complete this rear battery rack.



The POR15 showed up! This will protect the frame and battery racks...plus it will look great.

Build Session 12 (1 hour): Rear Battery Rack Flat Bar Bending

Work has been busy so I haven't had as much time as I would like complete the battery racks. Now I am leaving for San Diego for a week so don't expect any posts until the 28th or so...

I did get the rear box flat bar cut and bent into shape...My son Reece helped out.


We clamped the flat bar to an old steel skateboard grinding rail that Reece and I made a while back. Then we heated the flat bar with the torch along the bend line.


Then we bent it.


No problem...



A second set of hands makes it even easier.


And here is the finished pieces. I plan to weld them to the rear battery rack support tubes when I get back.


More parts showed up today: Ceramic heater, volt gauge, ammeter gauge, heat shrink, cable lug covers, motor mount


...and the gas shocks & hinges for the lift bed conversion.

Build Session 11 (3.5 hours): Rear Battery Rack Main Supports

Tonight I completed the main support structure for all three rear battery racks. Next I plan to add the flat bar supports that will hold the battery boxes.

Preparing to remove the forward cross member from the truck frame. Don't worry, the battery box support tubes will compensate for the removed cross member.


After grinding out the steel fasteners the cross member came right out. Then I was able to weld the new longitudinal battery rack supports in place.


Cross member is out...


Notching the frame out to make room for the outer battery rack support tubes.


I cut the support tubes to fit between the new battery rack cross members.


Welded in place.


Its getting too dark to continue...its looking good though. :)

Build Session 10 (3 hours): Rear Forward Battery Rack Support Structure

I spent Saturday morning building the main support of the two forward battery racks which will be located under the truck bed. It was very hot today (94F) and I did my fair share of sweating...especially while using the welder. :)

Prepping the forward bed mounts for welding...The 4 inch Makita grinder with a wire wheel worked nicely. I love that tool.


After double-checking my measurements I cut a piece of 1.5 inch steel tubing and welded it between the support plates that I built during my last work session.


Then I secured it in place between the forward bed supports and welded it in place on both sides.


The forward support is done.


Welding in the rear support tube of the forward battery box.


The UPS guy delivered my 2/0 gauge welding cable yesterday! I'll use the welding cable to deliver the 144 volts from the traction packs (batteries) to the speed controller, motor, etc... Welding wire is quite flexible and capable of handing high voltage and amperage demands. Red for positive and black for negative.


That's it for this weekend. Meg and I have tickets for Batman movie at the IMAX theater and it was time to get ready to go.

I hope to finish the "under bed" battery racks before Megan I head out for San Diego on Thursday. Stay tuned...

Build Session 9 (1.5 hours): Rear Forward Battery Rack Support Plates

I didn't have a lot of time tonight but I was determined to fabricate the forward main support plates of the front two battery racks located beneath the bed. These pieces will be used to elevated the front main support tube where the truck frame dips down.

I had planned to used my band saw and metal blade to cut these pieces however the .25 inch carbon steel proved to robust for my patience level.

...and so I broke out the cutting torch.



Yes, I know, its just a little guy...not quite like the large acetylene tanks back on the farm. But it gets the job done just the same and it fits in my suburbia garage dwelling.



I made a cardboard template then cut the pieces out.


I could have weld them in place just as they were but being the perfectionist freak that I am I was determined to grind them until both pieces were perfectly concentric.


Tomorrow I will weld one plate on each side of the frame right behind the cab. Then I'll weld a cross member support tube between them. You'll see...tomorrow.

Build Session 8 (4 hours): Let the Battery Rack Build Session Begin...

Jared and I stopped by Professional Plastics and Specialty Metals on the way home from work to pick up my order placed on Tuesday. Both businesses are located in Kent, WA within a few mile of each other. It seems like you can find just about anything fabrication related in Kent, Washington.

Both orders were a bit pricey...it seems like steel has doubled in price since that last time I fired up my welder!



I wasted no time as I was anxious to begin one of the installation build steps as opposed to the engine removal work. Yes, I am wearing my OSHA approved glasses, gloves, and flip flops. Actually most of this conversion thus far has been honored by the presents of my trusty old flip flops. (Don't try this at home kids...I am trained flip flop professional)


The first battery rack support is tack welded in place. I plan to complete all of the welds after most of the rack is built...just in case some of my calculations are flawed.

I hope the neighborhood dog walkers had the forethought to bring their welding helmets with them...I would hate to damage anyones retinas as they are strolling by.


The second piece of 1.5 inch tubing is positioned and welded into place. Dang...its getting dark already.



Once it became too dark to continue I decided to move into the garage and remove the clutch disc and take some measurements...both of which I will send to the machine shop in the morning. They will use the data and disc to mill out an adapter plate for mating my electric motor to my existing transmission. Man I wish I had a CNC mill...someday. :)