EV MX5 Conversion
(page 3)

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The remaining three out of the twelve battery's will live at the rear of the car. A hole cut out large enough for them was made using a 1mm cutting disc and I have to say was a little awkward due to the angled sides of the boot space.

Then a frame made from trusted 40mm angle was fabricated that sits in to the hole, the idea being that this will actually become part of the car and then support the the rear battery frame slides in to it.
The battery frame itself is made from 40mm & 25mm angle and some 25mm flat bar, like the other battery racks it is oversize to allow the use of foamex board for protection and insulation.

This picture shows the foamex board sitting in the battery retaining frame, which in turn sits in the securing frame shown earlier.
And here is proof that all the battery's fit.

Two bars that run across the battery edges will stop the battery's falling out should the car overturn.

Spare pieces of foam insulate the top of the battery's. Carpet can now be laid over the top of the pack, almost hiding them from view. A trip to the powder coaters and that's this part done.
To tidy up the unused cabling that would have originally gone to the engine, wires were traced back to the bulkhead and fuse box and if not required they were cut short and insulated with heat shrink, then bundled in convoluted tubing and tucked out of the way.

To join the battery's together I have opted to use 25mm x 3mm copper flat bar, where the terminals are not to close together the I will be using 95mm welding cable. Here you can see the bars have been insulated with large heatshrink
It's like Mazda designed the MX5 to be an electric car, this picture shows the 16amp charging socket, it just fits like a dream, great stuff really, the hammer wasn't even needed.
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