Electric Vehicle Conversion - 96 Toyota Tercel to 144v Plug-in Electric Car

Putting some Junk in the Trunk

The spare tire well provided a good spot to place the rear pack. We believed that we could fit 6 batteries in the front and 6 in the back. This provides a nice even weight distribution so we aren't messing the balance of the car up too badly with so much extra weight. After slashing out the trunk, Tom began setting up the battery tray and welded out the frame while I welded in the supports and cross beams. As a note, my welding is a lot like a drunken Pelican's landing. It isn't pretty, it is humorous to watch, but it seems to get the Pelican to where he needs to be.

Battery tray with initial battery placement. We put some plastic on the bottom of the tray and oriented the batteries so the main conduit fittings would enter in the right side of the tray. We debated the various battery types with the deep-cell and other technologies out there but with the cost of lithium-ion being pretty high and this is our initial prototype we went with AGM batteries and after explaining to the salesperson that we wanted 12, Tom got a really good deal with delivery. That helped a lot because they are a good workout when moving them around and jostling them in place.

And then we wrap the shell of the battery compartment with plastic. Tom had been working with a plastic welder but we weren't able to get a good seam so we fell back to metal strips on the outside keeping it tight. The bottom of the tray is a metal with venting to help prevent any intrusions into the battery compartment. With the AGM they are a lot less prone to leakage or outgassing but we still wanted to make sure they were protected.

Another angle. The benefit is that we still have some trunk space remaining so we can get the dougnut tire back in there and still have a little spare space for groceries and other items. We may put a plywood shelf on the top if the top panel gets too much deflection and maybe some nice avacado green shag carpet if the mood hits us.

Battery connections were an interesting concern. Most of the suggestions were to use a striker to hammer the lugs into place. Tom had an different opinion and created a hand rig that we could use a socket wrench to tighten.