June 22, 2004

Building the car: Installing the Kokam Batteries

First we remove the Cyclon batteries.

old batteries
Wires, plastic and wood are removed.
old batteries being disassembled
Next we lay in a layer of 40 mil PVC sheeting. This helps insulate the pack from the chassis. The silver tape is 'bundling' tape. It looks a little like duct tape but is easily removable and somewhat reusable.
PVC sheeting to insulate

Lowering the battery stack in was not difficult, but it was extremely important to have thought out battery cable connections from the beginning. In this case, the bottom cable is already attached before the stack was installed. The yellow tab covers the positive tab. Since it is on top of the stack it will be easy to attach a cable to.

stack in place (note bottom cable)

These two stacks are to be connect by the cable going from bottom of one stack to the other. We considered connecting them outside the car and then lower them into place but decided there was too much chance of tearing a tab.

Instead we put the second stack on a foam pedestal.

foam pedestal for attaching bottom battery cable

Space was tight but doable. Yellow tab covers the tab we needed to connect too.

cable to yellow tab

Once the cable was connected, the new stack was lifted slightly and the pedestal pulled out. The stack then lowered into place.

two stacks in!

The rear stacks were more of a challenge.

rear battery space

The inverters had to be pulled before we could lower the stack into place.

rear stack in place

PVC sheet cover, then thin metal.

cover the stack

Some foam to dampen vibration

foam to dampen vibration

Then the inverter. The weight of the inverter is carried completely by the aluminum blocks bolted to the chassis, not by the batteries.

inverter in place

With all stacks in place, the remaining cable connections are reachable.

connect the last cables

Using cardboard, we design battery covers. They are fabricated out of aluminum and bolt into place. On the drivers side, the front stack is 16 cells, while beneath the seat is only 8 cells. This allows us to put the weight of the driver as low as we can and still let him see the road.

driver side battery covers

The passenger side has two 16 cell stacks. The passenger seat is higher. It is not mounted for races, so this is not an issue. The air should flow from the central tunnel, through the battery stacks and exhaust by the diffuser. The arrow point to where the air enters.

passenger side battery covers

Ready for the seats!

batteries in, ready for the seats!


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June 19, 2004
Oct 26, 2006 Part 1


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