28 of the 60 cells I purchased will be mounted up front where the gas tank used to live. After designing a layout pattern, I made a plywood template to test the fit.
I used the plywood to layout the base frame. Once the pieces of angle iron are cut to length and clamped down with square corners, the frame is welded together. I oversized the frame by 3/16” (4.75 mm) so that the frame can be lined with a rubber mat.
After the base frame was completed, I made tabs that fit the gas tank mounting locations and tack welded them to the battery rack. Then I made the upper frame of the battery rack. The right front corner of the frame bolts into place and is designed to clamp the batteries securely in place.
Here is the rack populated with 28 cells. There will be a sheet metal base to support the cells, and open sides, as the cells in the trunk are fully protected from road splash. The top will be covered with an acrylic sheet to protect against voltage hazard, but still keep the cells visible - especially important if the car is ever displayed.
