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04-30-2011 03:18 PM Start of the Finish of the Battery Box
The end pieces still needed the rosette holes. Seven each end for a total of 14. They ate my lunch and my drill bits. Stainless steel is hard on bits.

There also needed to be 4 rosettes for the Dzus brackets, 2 stainless, 2 carbon steel.

Anyway, got all 18 holes drilled. The Dzus brackets are installed. Once all the rosettes are ground, the box will be ready to go in.


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  [Entry #357]

04-24-2011 06:23 AM Battery Box
I wasn't satisfied with the lid. It was too small. So, I made another one. Too big! Made a third one. A little small, but bigger than the first. I still had to add "corners" to the inside of the box so the gasket will seal, but it was better than the first one.

I need to weld in the Dzus brackets and grind all the rosettes smooth. After that, the box will be ready to weld in the car.


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  [Entry #356]

04-24-2011 06:19 AM More Trunk Welding
After massaging the right side of the roll pan, the angle piece was fitted and welded in place. Since it looks like the left side, there are no photos.

There was a large hole left from the removal of the spare tire holder. While looking at it, it became apparent there was also a hole at the other weld which was cut. A replacement piece was cut for the large hole and both holes were welded shut.

The battery box needs to be welded in. I want to at least cap the openings where the seat belt reliefs were cut. And, I need to weld lack of penetration areas from underneath. Not all that much left to do on the trunk area.


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  [Entry #355]

04-17-2011 10:23 PM Trunk Floor Extension
The angle piece was welded in on the driver's side. Can't get the grinder in there to finish the welds. No one will see them anyway.

The passenger side was a different story. After the opening was increased by a saw kerf width, the stretcher was used on the angle section to make it fit. When it required much more curve than the driver's side, it was obvious something was not right. The passenger side had a much larger "dip" in it. Instead of welding in the angle, the rest of the day was spent moving it out to match the driver's side.


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  [Entry #354]

04-16-2011 07:14 PM Beginning of the End for Trunk
Got the wiring harness out of the way. Removed the trunk releases. Pulled out the tail lights and the back up lights.

Originally, I was just going to seal the trunk floor extension to the roll pan. I knew I had too big a gap on the left side, but figured I would work something out. Then I got to reading about ghost lines and such. Decided to trim the extension back and weld in an angle.

I started with the easy side. The joke was on me. Neither side was easy! The left side is cut. The right side is about 2/3 done. Had to call it a day. Daughter was going to the prom.

Anyway, the left side is ready to weld. I have more cutting to do on the right side.


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  [Entry #353]

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