I will glu and rivet the boxes to the frame. This way I will not compromize the frame by welding, and the combined glue and riveting will hold for accelerations of 44 g vertical and 210 g horizontal! This is a factor 10 compared to the requirements. Of course the accelarations to accomodate for are not achived by the motor, but from braking and rolling the car in case of a crash.
The battery boxes are insulated with 10mm foam (camping mattress) to reduce the cooling in the winter.
First test mount of the rear battery boxes
The rear seats still fit!
And the trunk space is preserved
Time to grind the surfaces of the frame where the boxes will be glued
The boxes with insulation, connections and battery cells
The battery cables are kept in protective tubes. These are ordinary construction tubes painted orange.
The "drive shaft tunnel" has lots of space for the battery cables. The short black tubes are heat shrink that will eventually cover the cable glands
