'wittle 'wesistor (Mini Jeep)

Functional Artist

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To keep the battery cables, inside of the box, I'm going to mount the 48V 50A Circuit Breaker right onto the battery box
...in the top, left, front corner
SAM_7110.JPG
I masked the perimeter (to highlight the "cut-out" area & help protect the outer area)
...& drilled 5/16" holes (to establish the rounded corners)
SAM_7113.JPG
Then, cut 'er out (connecting the dots) with a cut-off wheel, in a Dremel
SAM_7115.JPG
Then, cleaned up, the "cut-out area"
SAM_7116.JPG
Test fit the CB
SAM_7117.JPG
Yup, that looks like a pretty tight fit :2guns:
SAM_7118.JPG
 

Functional Artist

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I used (2) pieces of 1" x 1" x 1/8" angle iron to make the battery mounting brackets
...kinda like this
SAM_7133 (1).JPG
The rear mount will be welded in place
...kinda like this
SAM_7120 (1).JPG
...& the front mount will be bolted in
...kinda like this
SAM_7119 (1).JPG
Safely "tucked" inside of the frame rails
...& (will be) hidden up/under the body ;)
SAM_7124.JPG
It doesn't "hang down" much lower than, the trailing arm brackets
...so, battery box to ground clearance, shouldn't be an issue :thumbsup:
SAM_7123 (1).JPG
 

BaconBitRacing

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Maybe diversify the product line. :thumbsup:
Like add a "waterproof" version, made with plastic grindings :smartass:
...& for heavy duty applications, a version made with metal shavings :stir:
You are now head of R&D. Saw-Glu Mu-Glu, with a portion of milk 🥛 added for stickiness and color. Chocolate milk version available too. :cheers2:

Saw-Glu, Made for You.
 

Functional Artist

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I used the CAD floorboard template (to mark)
...& cut out a front section, floorboard, out of some of that 18g. steel (same as batt box) :thumbsup:
SAM_7134 (1).JPG
Like this :2guns:
SAM_7137.JPG
But, after re-evaluating "the plan" I ended up eliminating the bolting flanges (cut 'em right off)
...& will transfer those duties (connecting the side panels to the floorboard) to the side panels :cheers2:

So, after re-trimming, deburring & then bending, it looks like this :)
SAM_7145.JPG
...& then here, dry fit, on the chassis ;)
SAM_7146.JPG
 

Functional Artist

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Test fit a CAD side panel on/with the steel floorboard, on the chassis :thumbsup:

Here is a pic of the front inside area
...showing how "nicely" the side panel, aligns with the floorboard :2guns:
SAM_7153 (1).JPG
Another view
SAM_7154 (1).JPG
Here are "before & after" drawings of the side panels :cheers2:
SAM_7169.JPG
The top drawing shows the side panels without a (~1") bottom bent edge (bolting flange)
...just a bent (~1") front edge (bolting flange) & hood line
&
The bottom drawing includes full length, upper & lower (~1") bent edges (that can be "used as" bolting flanges)

IMO adding (~1") bends, to the top & bottom edges, should make the side panels stiffer (stronger)
...& should also, end up making them smoother too (reducing waviness) ;)
 

Functional Artist

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Rear section of floorboard (Mechanical Drawing)
SAM_7190 (1).JPG
Rear section of floorboard (CAD)
SAM_7172.JPG
Rear section of floorboard (transferred to the steel)
SAM_7181.JPG
Rear section of floorboard (100% cut out)
* Used the straight edges & Vice Grips as a guide to help make straight cuts
SAM_7184.JPG
Rear section of floorboard (manually installing the front bend) (Vice Grips X 6) ;)
* Bend orientation: upwards
SAM_7192 (1).JPG
Rear section of floorboard (front bend, installed)
SAM_7195 (1).JPG
Rear section of floorboard (manually installed the mid-bend)
* Bend orientation: downwards
SAM_7197.JPG
 

Functional Artist

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To mount & help support the floorboards, I added a few pieces of 1" x 1/2" x 1/8" steel channel

* The (2) middle pieces will also be used to mount & support the seats
SAM_7207 (1).JPG
Here's a look with the floorboard(s) "in place"
SAM_7208 (2).JPG
Side view
SAM_7209 (2).JPG
Seam looks "pretty tight" :thumbsup:

* I aligned the front piece of steel channel (under the drivers feet) with the seam, between the front & rear sections of floorboard
...so, it supports the connection of the (2) pieces
...& strengthens the "step in area" too
SAM_7210 (1).JPG
Here's a look at the supports under the floorboard & seating area
SAM_7211 (1).JPG
 

Functional Artist

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I've been adding a lot of steel to this chassis
...so, I figured I weigh it, just to see where we are at :thumbsup:

So, I "stood" the frame up (on the rear bumper)
...& put 'er on the scale
SAM_7215 (1).JPG
Looks like it comes in right at 46 lbs.
SAM_7213.JPG
Then my wife comes around the corner :mad2:
...& asks "is that my bathroom scale?" :huh:

Um...well
...I was just checking on...:innocent:

I mean...it won't hurt anything
...it doesn't weigh as much as...:eek: o_O
Um...I mean...(smack, smack, smack) :horse:

Uh...to be continued (smack, smack, smack) :ack2:

Uh...I mean...maybe (smack, smack, smack) :surrender:
 

Functional Artist

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You better put it back, I told you not to take it! Mrs. Function Artist, I told him not to take it. But would he listen? Nnnnoooo! Darn kids these days!
I figured it was you :furious2:

(Remembering)
Just before she came around the corner, the phone rang
...& I heard her say "Oh REALLY! :stir:
...& then, around the corner she came :ack2:

Thanks Denny :mad2:

The moral of the story:
I learnt that I'm ONLY allowed to use her scale, when she ain't home :cornut:
 

Functional Artist

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Mini-Jeep
Seat(s) (diagram)
SAM_7222 (1).JPG
Seat(s) (bases)
SAM_7217.JPG
Seat(s) (passenger seat dry fit)
SAM_7219 (1).JPG
Seat(s) (~36" seat back to pedals)
SAM_7227 (1).JPG
Seat(s) (~10" seat to steering wheel)
SAM_7230 (1).JPG
Seat(s) (~14" seat back/bottom to the steering wheel)
SAM_7231.JPG
 
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