Fabricating a battery box to accommodate 4 Chevy Bolt battery modules (~24kWh) where the engine used to be is not a trivial job, but a necessary one. I decided to put all 4 batteries up front instead of 2 in the front and 2 in the trunk for the following reasons:
- Wiring simplicity
- Better airflow/cooling capabilities
- Closer to original weight distribution
- Preserves original trunk space (The gas tank area in the trunk that could have housed 2 batteries will house 2 chargers and 2 DC-DC converters.)
- Single drop in “module” for ease of installation/maintenance.
The base fabrication starts out with 1-1/4″ steel angle that I’ve cut and welded to form the bottom frame of the box. Aluminum panels will be fastened to the sides of the framing to form the box. There’s also a “subframe” that I’ve made using 1″ square steel tubing and 2×2″ angle. This subframe will support all 4 batteries, and will be riveted into the XJ-S’s frame.
