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My upgrade from DC to AC drive has prompted a lot of questions. I'll try to answer some here. First of all I redesigned my battery compartment to better utilise the vehicle interior. I installed a false floor and sandwiched the cells between various layers to keep them warm/cool as required. Better thermal management = better life and performance. |
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Layer 1, Insulation 25mm Kingspan silvered foam. |
Layer 2, 12mm plywood sheet, drilled for 28 cells. Securely bolted to metal floor of vehicle. |
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Layer 3, 12mm 300kg strapping and old electric blanket heater wires which run under cells. |
Layer 4, Cells installed, strapped down individually with side Kingspan insulation in place. |
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Cell connection close up with cell protector in place. Cell strapping is 2 per cell tightened to about 100kg. |
Cells installed and wired up. Neat I think! Each cell has it's own sheet of 9mm plywood cut to fit on top to ensure adequate and even cell compression. |
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Layer 5, 3mm flexible foam sheet to insulate next silvered layer from any loose cell connections, and to fill gaps in any badly cut sections of side insulation. |
Layer 6, 25mm Kingspan silvered insulation. |
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Layer 7, 9mm Plywood load surface. Bolted through floor to metal of vehicle. |
Layer 8, finally carpet and rear 5mm Foamalux plastic end covers in place. |
