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This is the rear battery box, constructed of 5/8" MDF (Medium Density Fiberboard). I chose it for ease of construction, relatively light weight, and design flexibility. It will contain ten four-packs of cells, with the remaining two to be placed below the boot (Brit-speak for trunk) floor in place of the gas tank.
Four four-packs are placed at the rear of the box, and are positioned to clear two bumper reinforcements.
Side view shows space for cable connections. This pack will be logically split into two packs of 32 volts and 20 volts for cabling purposes.
Six four-packs will be placed in the front of the box standing on end. This provides the highest weight density closest to the mid point of the car just aft of the axle for better weight distribution. At 27 pounds per four-pack, the entire assembly weighs approximately 290 pounds including the box.
Another side view. The front is cut down to clear the axle hump for placement in the boot. The front six four-packs are connected as a single 76 volt string. The vertical MDF surfaces will provide mounting points for the two rear fuses and the BMS control components.
Box in position in the boot. The battery packs will need to be lifted over the axle hump and connected in place.
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