The Trunk

Posted by admin May 22nd, 2009

I needed a good dry place to put all of the high voltage components. This includes the Zilla controller, the main contactors, the DC to DC converter, and the charger. The most logical place was in the rear of the car. There isn’t a trunk but there was a nice area just behind the rear suspension that was empty. I decided I would fiberglass in this area with and make a hatch to access it. It would be water tight and away from any road dirt. As an added bonus if done right I might even have enough space to store a small bag or brief case.

The project started by cutting out the hatch with a dremel reinforced cutting wheel being very carefull to make clean straight lines. This was going to be very visible so it needed to be clean looking.

Foam was glued to the inside of the opening to form a lip. Once dried I used a dremel sanding drum to carve out a shape in the lip that would allow for a rubber seal as well as as a trough to carry away any water that came in. This was then fiberglassed.

The floor of the trunk was formed with foam and fiberglassed as well.

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