Next was to get going on some alterations to the deck and battery case… Got the case squared up to the deck and laid out where the threaded inserts would be located. Put masking tape down on the edge of both the deck and the case for easy marking, making it much quick to relocate the case after drilling.
Made marks for realignment and drilling… sorry no photos of drilling, but first I drilled the wholes through the battery case, then I realigned it and clamped it back down to the deck, used a drill bit back into the holes to start/mark the hole in the deck… switched to a larger bit and drilled the holes in the deck.
So the holes are great for reducing some weight, but I’m doing a bottom mounted battery, so can’t have it exposed to the elements.
started by masking over the holes at the top of the deck and then masking at the bottom… only cutting the tape at the bottom.
Then I filled in the holes with expandable foam… I had some from smooth-on, so just used it, but if you go this route I’d simply use insulation foam from Home depot… This will fill the void while staying nice and light…
easily cut the excess foam off with a scalpel.
Then dug out about an 1/8 of an inch (currently working from the bottom of the deck) I want to make sure that this is completely water tight, so multiple layers of material will be used. Also, created a bit deeper trench around the edge, as this is the most crucial space to ensure adhesion with the next layer.
Filled in my trench and coated the top with PC-7
Not photographed is after the first cure I spoted some little holes, so I ended up doing an additional skim coat… all sealed up now. and this is basically where I’m at…
The PC-7 is all cured I had also drilled the deck and implanted the threaded inserts… I also used PC-7 to insure they remain secure for a very long time. With that done and waiting for the wires to arrive for the next steps I decided to put the wheels on and push it around a bit… makes me even more excited to get this thing some power…
One thing coming up that makes me a bit uncomfortable is extending the motor sensor wire so it’s long enough to reach the VESC-x. The connector on it is already the right size, so my plan is to snip the wire and solder each wire back together long enough to reach and then heat shrink that back together… this seams to be the cleanest approach, but is a bit more surgical than I’ve experience prior to this. How does this sound @trampa? I think I’ve read somebody doing it this way but it was awhile ago, anybody actually done it like his?