Here's what I had in mind to hold the batteries in place and it's also for attaching the cover. There will be rivet nuts in all of the holes and everything will be fastened from the outside this way.
Don't know if the triangular shapes are necessary but it should be sturdier that way.
Here it's in the battery box.
Might have to add something else in the middle of this battery box though since there are 2 rows of batteries in it. The other battery boxes will all have 1 row so it should be easier for those.
I've continued with the 3D drawing.
I think the only way to secure the batteries is to place an L-profile of the same material as the battery box at the top and bottom and fasten them from the outside with bolts. I want to use rivet nuts with this and seal it with rubber to make it waterproof. No idea how else to do it.
I'm also not really sure yet if the batteries will actually be placed in this position, will have to wait till I receive the batteries. Only then I can see how they'll fit.
Today I received the aluminium plate. Also a new front sprocket and some new dust caps. I ordered these for the steering rod end, however these are for the ball joints. Again a delivery with the wrong parts. Oh well, I assume this will be solved as well.
The current steering rod end dust caps are already broken while I haven't even ridden on the quad bike yet. They're not really of great quality.
I already gave the aluminium plate and the steel blocks to my friend, now I have to wait again till they're routed. Could maybe take 2 weeks, hopefully faster. But if it gets done well it's worth the wait.
The front sprocket barely doesn't fit over the motor's axle, the hole will have to be made just a bit bigger. And maybe also remove the threads in the mounting holes, the sprocket will be mounted differently than how it normally is in the Loncin engine anyway so I wouldn't be able to use the thread on the sprocket itself.
Was a bit bored today waiting for the plate for the motor mount to arrive. So I played around a bit in SketchUp and replicated the batteries I will be using. Think it turned out pretty well, first time actually using the program.
Also made one of the battery box (the biggest one) in which the batteries will be held together. And I'm in luck, there are 2 sizes given for the width of the batteries on the supplier's website but the smallest size seems to be correct. I always assumed the larger size to be correct. This will give me another 3mm to spare for each battery which is quite a lot really. Will be even easier to place them.
Only problem is I have to make sure they won't be able to move inside of the box. That's why I'm making this 3D drawing, to discover a solution for this.
I also filled up the box with batteries, pretty fun program. Easy to work with.
Think I'll continue and add the BMS boards and connections as well.
Posted on 4 April 2013 at 05:10 pm (CET)
Got something again today, from Belgium this time. It's definately becoming an international quad bike this way.
Blank rear sprocket (530) with 44 teeth. Only still need the holes drilled. My friend who is making the motor mount will also do this so it'll be alright.
I almost have all parts complete now, just a few more small things. And ofcourse the batteries but they should arrive here in 2-3 weeks.