Build Session 16 (90 mins): Rear Battery Rack Welding Cross Member

Yes, I'm still working on the rear battery rack. :) One more day and I should have the rear rack finished.

First I prepped the flat bar cross member that I bent yesterday. I'm using the wire attachment on the Makita to remove the rust.

Prepping the frame...

Measuring the distance at the top of the new cross member to make sure that its slightly more (1/2 inch) than the 31 inches at the bottom of the cross member. This will allow the battery box to slide in easier. The cross member is clamped into place and I tapped it into position with a hammer.

Then I welded the cross member into place.

In case you're wonder what welder I'm using...

It's a Lincoln Power Mig 140c Welder. I'm not using MIG right now just .035 inch Flux Core Welding Wire and it seems to be working great for this application. The bottle on the back of the welder currently is Argon which I use when I am welding aluminum. I use argon with the spool gun pictured below.

.035 inch Flux Core Welding Wire

100 SG spool gun used for welding aluminum and other types of metal.

Anyway, back to business here...Then I wire brushed the area where the flat bar cross member supports meet, clamped them together, and welded all three of them in place. That's it for tonight.

Build Session 15 (45 mins): Rear Battery Rack Cross Member Bending

Not much time again tonight...but it was enough to cut and bend a piece of 3 inch flat bar for the rear battery box rack. This piece will provide cross support for the rear battery rack. The flat bar is 1/4 inch thick. I cut it 68 inches which turns out to be a 1/2 inch or so to long (I'll fix that tomorrow when I weld it in place).

I convinced my oldest son Matt to step away from his laptop long enough to work square up this piece and help me bend it.

Using the torch to heat the steel...

Matt is learning how to use the torch...he did a great job!

Me...trimming the acetylene...

Preparing for the third bend...

Not much leverage so Matt used the sledge on this bend...

The new 3 inch cross bar sitting in place... I plan to trim the ends down an inch and weld it in place tomorrow.

A video of Matt using the torch.

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...