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...