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Step 6Battery Tray Fabrication
Using steel angle iron, we fabricated three trays for batteries. One tray holds two batteries in the engine compartment, while two smaller trays are mounted like saddle bags on the rear of the bike.
The original design for the battery trays used beefy 2" angle iron to insure that they could support the weight (about 50 lbs. each). This was not a great choice. It added far more weight then needed. A redesign of the bike uses slightly smaller batteries, which helped in several ways.
A newer re-design of the bike uses smaller batteries. Now all four batteries could fit into the engine compartment - eliminating the need for the two rear saddlebags. The new design also replaces the 2" steel with 1/2" angle iron as well as gigantic zip-ties. Overall, this new design saves a ton of weight, which helps to offset the smaller range of the smaller battery set.
The original design for the battery trays used beefy 2" angle iron to insure that they could support the weight (about 50 lbs. each). This was not a great choice. It added far more weight then needed. A redesign of the bike uses slightly smaller batteries, which helped in several ways.
A newer re-design of the bike uses smaller batteries. Now all four batteries could fit into the engine compartment - eliminating the need for the two rear saddlebags. The new design also replaces the 2" steel with 1/2" angle iron as well as gigantic zip-ties. Overall, this new design saves a ton of weight, which helps to offset the smaller range of the smaller battery set.
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