Junkyard #ebike build 9.3: box is together.

It turns out that the battery *just* fits into the box via the top, if I wedge the big end in first and skew the circuit end a bit as I insert.

I pre-drilled and countersunk the top and bottom panels, then used them as a template to drill holes in the corner posts.

I used screws and nuts to secure the bottom of the box, and heat-set inserts on the top side. I wish I had made the part I'm screwing into quite. a bit thicker.

I'm going to make a gasket for top and bottom to seal the box, but I rounded the corners on the linisher and the box fits the bike just about perfectly. I'll use webbing straps to hold it on the cargo rack, I think.

Junkyard #ebike build 9.2:

I found some manky plastic panel (some kind of acrylic, but thick enough that I 'm not concerned over brittleness) in the attic. It's so old that the paper coating won't come off (soaking in hot water as I type). The 3D printed brackets are intended to interface with side panels that have a rebate cut on them, which I did with a router table. Notched on a bandsaw, the box fits together snugly (and will have foam padding on the inside).

This #solarpunk box made from ugly recycled plastic will next get the brown paper coating removed painted a nice coat of paint.

Junkyard #ebike build Part 9: BOX RETHINK

Three things:
* I can't find my fine-tip heat gun that I use for plastic welding
* This recycled PVC is way too wavey to be used without welding it immobile
* Since writing "why I don't just 3D print?" in last part, I remembered that I ALREADY SOLVED THIS for a client prototype, by designing 3D printed box-corners that print fast, combinning with sheet material for the panels.

Here are my abandoned #solarpunk box ideas: