Punky Pewster lent a helping hand in building a couple cardboard boxes, one of them being a mock-up of a 12V car battery and the other being the battery box itself.
I needed to build a platform for the 12 volt battery in the electric car project but had no structure onto which to work. Placing the actual battery into position would have meant using supports that would get in the way of building the structure itself because of the weight, so lightweight mock-ups were the way to go!
Step 1. Build a cardboard battery.
Step 2. Build a form around which a tray/platform can be built. This is built a bit on the larger than needed size, knowing it will need to be cut down but still want space all around the battery in case a different size batt is installed in the future.
Step 3. Build a quick lightweight platform in place using cardboard and wrap with carbon fiber.
Step 4. Fit/Clearance check before permanently bonding stuff together.
Step 5. Box/Tray is bonded to the platform and the height trimmed down a bit. A hole is added into the box on the right side which is access to the mounting bolt. Since the platform was cast in place directly on the car’s chassis, it indexes its location automatically and only needs to use a single bolt to hold it in place. This particular bolt was pre-existing and connects the front section of the chassis to the center part. It’s a 5/8" diameter bolt and is way underloaded.