build an Aluminum side-mount batterybox:
| In the winter
of 98/99 I was looking at my sled, trying to decide what my next
project would be. I decided to pick the ugliest part of my bike
and build something cool to replace it. The ugliest part just
had to be the batterybox, I started making some sketches and designs,
using the CAD-model of my bike (Cadbike
#1), and came up with a sidemount batterybox made of aluminum
and stainless steel, which happen to be my favourite materials.
|| After I made the
Cad-drawings of the 3 main aluminum parts, a friend at work cut
the 3 parts out of some 30 millimeter thick chunks of aircraft-quality
aluminum, using a CNC wire erosion machine. The cuts were only
0.2 mm wide! Then the top and bottom parts had to be made hollow,
leaving only 6 mm's of material on all sides.
| The top part I
did at home using my own little milling machine on a Friday night,
it took 6 hours to remove all that material! I decided to do the
bottom part at work with a much bigger milling machine, this took
only 1 hour.
The round grooves in the top
cover I did at a friends machine shop; he has a big milling
machine with a digital readout, so I could use the coordinates
generated by my CAD-program.
|| All other parts
are AISI 316 Stainless Steel, the ground-wire is connected to
the inside of the battery-box so only one wire comes out of the
At the moment I have taken
it apart for some small modifications so I took the opportunity
to make some pics.
To be continued!