[sabahtom]

Any reason not to use .5mm roofing sheet? This material is readily available in my town, Al sheets probably have to be shipped in. I'd have to use 2mm stainless steel angle bar for the frames I guess.

[bjfreeman]

think of corrugated boxes soaked in Resin. Wrapped with fiber glass or Carbon Fiber.

[sabahtom]

I was thinking of roofing because I'm near the equator, and the large corrugations would be good for airflow. Hoping to get away without forced ventilation, heard a guy with a similar battery pack to mine in Seattle doesn't need forced ventilation it even in summer. Corrugated boxes with resin sound like good insulators?

[bjfreeman]

yes they are good insulators, for your situation, the problem is your ambient temperature. to have cooling the outside air must be able to absorb the heat generated.
if your ambient temperature is high you need to think in terms of a swamp cooler.
I have a liquid cooling system, with a radiator. I have a swamp cooler attached to the front of it, for climbing long mountian passes, in the summer
I am in the Seattle area, we only get Hot in July though Sept, and average of 75.

[sabahtom]

I've looked at swamp coolers but the rel humidity here is normally 80% plus. They're not recommended for houses at the level of humidity, maybe it would still work with the high air flow from driving?

We have heavy rain and a lot of puddles on the road, one of which killed the diesel motor on my donor car. For some reason Kia puts the air intake on this model next to the left front tyre, nice and low.

If I do need forced cooling I'll have to run two ducts (only two long batt boxes) from the aircon. It'll have to be using cabin air.

[bjfreeman]

seem you have additional consideration of Corrosion and mold.

[sabahtom]

Originally Posted by bjfreeman

seem you have additional consideration of Corrosion and mold.

Aluminium should be ok with getting wet. I'm planning on using galvanised stainless steel studs for the terminals. The battery connectors are galvanised mild steel.

I didn't think about mold - if there's enough airflow around the battery it should be ok.