Little update after a bit of work the last couple of days: battery box, inverter and high voltage junction box all now in and ready for some wiring – both high voltage and control. Got some of the 3D printed connectors/adaptors I’ve knocked up in as well.

Photos show me mocking up the location of the inverter with cardboard and wooden wedges so I could measure out the new steel for the ‘cage’ that combines the motor mounts and frame for this and the HVJB. Measured up, pulled it all back out (again), and welded it up. Then slapped on a coat of Hammerite. Eventually I want to take this all off and remake it a bit better, or at the very least repaint it properly.

Other pics include the lining of the battery box (cut from EVA foam (yoga mat) and glued in), some connector close-ups, and it all now in situ.

• The orange high voltage connector has a cover that slides over it and screw-in locks that also hold the sheath for the 35mm2 cables. I’ll post some photos of that soon.
• The black connector is a combination of a salvaged plug and socket and a 3D printed front plate. The plug that came with it lacked any sort of cowl or sheath so I’ve also designed and 3D-printed one. I’ll post some photos of this as I go through the wiring too.

Issues: I had to push the inverter so far back to clear the battery box that there isn’t much space for the AMPSeal connection that carries all the control/communication wires or for the water cooling inlet/outlet (TBC). Think I can clear some space for the cooling with some slight bends in the brake pipes that run across there.

AMPSeal is trickier but have a plan: the ribbon cable I have in there that connects the control board to the AMPSeal is far too long. So will swing the connector through 180 degrees and mount it under the inverter where there is now loads of space. OR come up with something completely different.

Next step: running CANBus, 12V and HV cables. Then I’ll think about cooling again – got some ideas…