Front battery box and connection

Time for the front battery box that goes on top of the motor. Also here I had to compromise due to space limitations. Instead of having 3x8=24 cells it will have 3x7=21 cells. So the total of the car will be 2x22+21=65 cells. The total pack voltage will be 65x3.2=208 V instead of the 218 V that I first designed for. This will reduce the range with 5% (95 km instead if 100 km) and the maximum power with 10% (72 kW instead of 80 kW). I think it will be enough though, the max power of the gasoline engine was 55 kW! It will also reduce the power of the heater from 4.5 kW to 4 kW. This is more of a concern in our cold country!

The front battery box with insulation

The front battery box is mounted on two 30x50x4 mm aluminum U bars which in turn are mounted transversely on the front bars of the Audi frame. The frontmost bar is bolted to the frame using nut rivets and the rearmost bar is glued and riveted to the frame. This way the front bar can easily be removed in order to remove the motor and transmission.
The battery box is bolted to the U bars using nut rivets.
There will be a couple of components mounted on the battery box. Today I mounted the front connection box which holds a couple of connections bars and the fuse for the DC/DC and heater. On top of the connection box goes the Anderson power plug by which the battery can be disconnected from the motor controller and other systems.

The front battery box, the front connection box, and the red power plug

The + cable from the rearmost batterybox goes into the front battery box on the left and the resulting B+ from the whole pack goes out the other end (obscured) to the power plug.