corbin dunn wrote:
> Hey gary -- good point; I considered 1/4", but it is just so
> heavy...and the bug is already weighing more than I hoped! I just
> dropped my front batteries in the front trunk, and I think I'm going
> to need new shocks

>
> I'll definitely let everyone know how the 1/8" end plates work out
> once I get the thing driving. I have a big hill (highway 17, in
> Santa Cruz), which will definitely test the car out on a daily basis.
>
> corbin
>
> On Dec 31, 2010, at 8:03 AM, gary wrote:
>
>> I'm not sure how much pressure is required on these cells to stop
>> them
>> from bowing out on the ends but I've seen a couple sets do that.
>> Maybe
>> just under abuse but I don't know. It seems that the 1/8" aluminum
>> plate and straps may not be rigid enough across the width to prevent
>> gradual bowing out of the cells. This is not based on any real
>> knowledge, data or calculations - just a thought.
>>
>>
>>
>>
>> On 12/30/2010 10:15 PM, corbin dunn wrote:
>>> Hi Adrian,
>>>
>>> Everyone else has given great advice. I ended up using 1/8" thick
>>> aluminum plates that I "fabricated" myself out of a big sheet. I
>>> also used a strapping kit similar to Martin's. I bought mine for
>>> $80 on ebay (5/8" mini polyester strapping kit). Don't get larger
>>> than 5/8" with the Thundersky cells -- it won't fit in the grooves
>>> on the side of the cells.
>>>
>>> I literally just finished strapping my cells together last week,
>>> so this is all fresh in my mind. I put together a blog posting
>>> detailing the steps:
>>>
>>> http://www.corbinstreehouse.com/blog/2010/12/plug-bug-strapping-thundersky-batteries-together/
>>>
>>> In regards to your question, here is what I did: I added 1/8" on
>>> each side (for a total of 1/4"). However, I found my box was too
>>> tight when made to that size, and I couldn't easily drop in the
>>> cells. Instead, I recommend adding another 1/8" on the side. I
>>> ended up cutting my box and welding it a little wider to get them
>>> to fit. I just finished a post on my front battery box for my '69
>>> bug, outlined here:
>>>
>>> http://www.corbinstreehouse.com/blog/2010/12/plug-bug-front-battery-box-fabrication/
>>> -- includes what happens when the box is sized to fit

>>>
>>> I also posted my sketchup files and details in this posting:
>>>
>>> http://www.corbinstreehouse.com/blog/2010/12/plug-bug-battery-box-design/
>>>
>>> Have fun!
>>>
>>> corbin
>>>
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