Installing the second battery pack

The second battery pack installation has been done in very small steps not disturbing the every day driving needs for the car. The pack takes about 1/3 of the space in the trunk which still leaves me with a good enough space for a few shopping bags.

 

The pack is mounted in a housing made from plywood. Each cell is attached to the housing bottom using threaded rods.

 This photo shows how much 24pcs of Winston LYP60AHA takes space from a -87 corolla hatchback.

Using this type of PCM causes a lot of wiring inside the batterypack. In here the cells are connected in series and the PCM's cell voltage monitoring wires are connected.

A 50mm diameter PVC tube was mounted under the car to the place where the exhaust pipe and gas tank used to be. The tube acts as a conduit for the rear battery pack cables.

Power and control cables to the rear pack are fed to the spare tire space under the rear battery pack enclosure. Now all the hard work is done for the second battery pack installation. A few more late evenings will be needed to finish up the connections and to prepare for functional tests!