Ninjanick's 818S Build Thread

[ninjanick]

Trying to figure out the best way of mounting the controller and charger. I plan to mount them on the rear 1.5" square tubing where the firewall installs. The charger and controller weight about 25lbs. each. I'm going to try to pick up at minimum 2 and possibly 3 mounting locations on the actual frame, but I'm trying to figure out the best attachment method. I don't want to buckle the square tubing, so I'm thinking of drilling a slightly larger hole on one side for a spacer to be installed. Should allow me to properly torque the hardware without risk of buckling the tube. I don't trust rivnuts ... or should I?

[Bob_n_Cincy]

Trying to figure out the best way of mounting the controller and charger. I plan to mount them on the rear 1.5" square tubing where the firewall installs. The charger and controller weight about 25lbs. each. I'm going to try to pick up at minimum 2 and possibly 3 mounting locations on the actual frame, but I'm trying to figure out the best attachment method. I don't want to buckle the square tubing, so I'm thinking of drilling a slightly larger hole on one side for a spacer to be installed. Should allow me to properly torque the hardware without risk of buckling the tube. I don't trust rivnuts ... or should I?

I used a 1/4 revnuts all over (maybe 50). Probably a dozen 5/16 -18 revnuts to mount heavier stuff. I trust them. Get a good tool.
I used zero 3/16 pop rivets and only used 1/8" pop rivets in thin aluminum panels.
Bob

[ninjanick]

I used a 1/4 revnuts all over (maybe 50). Probably a dozen 5/16 -18 revnuts to mount heavier stuff. I trust them. Get a good tool.
I used zero 3/16 pop rivets and only used 1/8" pop rivets in thin aluminum panels.
Bob

What material (rivnut) did you use? I'm guessing steel for strength? Would it be better to try and pick up as many locations on the frame as possible or mount box to plate, then mount plate to frame?

Would you recommend the same method for something heavier like the battery boxes? My heaviest box is 105lbs. worth of batteries.

[Bob_n_Cincy]

What material (rivnut) did you use? I'm guessing steel for strength? Would it be better to try and pick up as many locations on the frame as possible or mount box to plate, then mount plate to frame?

Would you recommend the same method for something heavier like the battery boxes? My heaviest box is 105lbs. worth of batteries.

ALL yellow cadmium plated steel revnuts.
For something <5 lbs (over flow tank, hose support, electronics box) I would use 2 to 4 1/4-20 rev nuts.
I used 1/4 revnuts to mount all my bode panels to the frame.


For something 5 to 25 lbs (Radiator, small ATV battery, accusump) I would use 2 to 4 5/16-18 revnuts.

For 100 lbs battery boxes, I would weld in 1/8" x 1.5" x 1.5"angle iron frame and have a strap holding them in that was strong enough to prevent batteries form coming out in case of a roll over or collision.

Just a note from personal experience. use a insulation layer (GPO3 fiberglass) between the cells and any metal surface.
Bob

[ninjanick]

Attempted to weld in some gussets on the rear battery box. Had to since the bottom extends about an inch out due to a battery configuration change I made post frame powdercoating. I ended up sinking in too much heat and the side buckled. Luckily I still have room to fit all the cells in. Just doesn't look great