![]() One side has an additional T-bar on the base which divides the battery cell section of the box from the BMS section. The short bottom edges are right-corner-bars which will be the mount points for the plexiglass cover. The long bottom aluminum side edges are T-bars to increase the stability of the box and add an outer lip for mounting the box to the camper floor. Sheet aluminum sides are secured together with aluminum bar edging and aluminum rivets. The aluminum portion of the battery box effectively composes three out of the six sides of the battery box. Which means we frequently paused to test fit different parts of the case as it comes together. The greatest challenge is to ensure that the case is as precise a fit as possible. We are already an experienced riveting team, having buck riveted thousands of bonds while refurbishing our Avion truck camper. Assembling the CaseĪfter all the research into materials and design, assembling the case is remarkably straight forward. But extruded aluminum bars, rubber, and plexiglass solvent need ordering. Fortunately, we can use a scrap aluminum sheet from our Avion build. After sketching out several potential designs and identifying shortcomings, we settle on a final layout and start ordering the materials. Instead, we will take advantage of aluminum’s flexibility to pull away from the side walls while installing the battery cells and then securing them together to bind the batteries in place. And with it, so is the design of the box. The materials are all falling into place. Pealing the backing from adhesive on a rubber strip. As soon as we settle on making an aluminum case, we decide to line the interior with rubber as both an insulator, shock absorber, and means to ensure a snug fit for the batteries in the case without damaging the cells. It is also used as padding to lessen sharp impacts. Rubber is a common insulator for electrical circuits. Cutting sheet aluminum for battery box sides. Happily, this challenge also inspires a larger solution. While aluminum’s light weight and strength are ideal for housing a battery, it is critical that we this metal as far from the battery terminals as possible to avoid electrical shorts. Now, as I discussed when choosing a material for bus bars for this battery, aluminum is a highly conductive material. We settle on staying true to the camper’s roots by making an aluminum case. We also want a solid section to bind the batteries in place. This makes plexiglass the obvious choice for the display sections of our battery box so that people can see the batteries. ![]() It is a common material for RV windows and other clear surfaces subject to impact. While plexiglass hasn’t been part of our build process up to this point, I have a history using it on past projects. We want to make a box using materials that we can work with our own tools and skills. But molding plastic is something better managed on the assembly line. This is a simple and budget-conscious solution. ![]() Most battery boxes are made of molded plastic. ![]() To do this, we first dig into what materials will balance our need for strength with transparency. We want our box to be durable, supportive, and transparent. Electricity goes in to charge the batteries and is stored until it is drawn out to power something else. If you look at most batteries used in RVs, you’ll see a fairly standard exterior: a positive and negative terminal peaking our of a plastic box wrapped in branding and instructions. Like everything else, we will build it ourselves. We want the box to double as a display case, laying bare the guts of our homemade batteries.Īll of this means that any run of the mill retail case simply won’t do. With all the custom work we have put into these batteries, we want to be able to display them for educational purposes when we give tours of our camper. Along with functional needs, we also have an aesthetic preference. So the box will need to include a shock-resistant design to protect the batteries. Since this is a battery that will be in our home on wheels, it will be subject to the bumps and jostling of the trails we travel. ![]() Along with keeping components in, the box also keeps hazards out by protecting the cells not only from impacts but also electrical shorts.īeyond the typical role of a battery box, we also have our own specialized needs. It securely houses the battery cells, a battery management system (BMS), and electrical connections that make up the battery. ![]()
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