Todays task was mounting the mid-pack disconnect on the lid of the front battery box. The bit that'll sit inside the battery box is fairly large compared to actual plug-y bit so it needs some room. But I also didn't want to waste surface area on the lid of the box where I could mount other stuff.
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The 'in' and 'out' connections are there on the left. I had to trim down the orange plastic cover so that the cable lugs I'll use will fit. I also didn't want to put too much of a bend on the cables so left some room to the left.
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I had already made a template out of cardboard, so just transferred it to the lid.
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Cutting it out was fiddly and it didn't come out as tidy as it was going to be in my head. But the plug hides any innaccuracies.
The only remaining problem is covering up the fuse bulge. I was wondering about 3d printing a cover. But a fellow EV-converter suggested getting a small baking tray to stick on there - which is a great idea!
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I also did some fiddling with high voltage junction box parts. The original design assumed one battery, so there's a fuse in there. I'll have a fuse in each of the (2) battery boxes now instead. I will still need the small fuse for the heater, but the big one can go. I'll probably also switch to a smaller precharge contactor.
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Bonus moody #mustang pic.
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Christian