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Old 10-20-2018, 02:51 PM   #21
radair603
 
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

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Originally Posted by Midwestdrifter View Post
Looks good. One suggestion. Do not rely on that ratchet strap to hold the batteries in an accident. The same goes for those screwed down right angle brackets. That battery will shear those right off, and snap that strap.

I don't know how your cabinets are secured, but sheetmetal screws into the floor and walls are not sufficient by themselves if you have anything besides clothing and lightweight items in the cabinets.
Thanks for your input. I have been contemplating how to secure the batteries. I have plenty of angle steel on hand but attachment is still limited to the 3/4" plywood they're sitting on and shear strength of the fasteners. The ratchet strap is rated for 5k lbs but maybe I'm giving it too much credit.

The cabinet is secured to the van wall with eight 1/4-20 bolts into rivnuts as well as eight screws into the floor. I can also screw into the 1/2" plywood panels bolted to the van walls if needed, but it seems solid as mounted. I could attach to at least one factory tie down in the floor, I will take another look at that. There will be a fridge in the middle bay.
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Old 10-20-2018, 03:14 PM   #22
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

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Some rewarding progress lately. I got both lower side panels (garage area) installed after tidying up the wiring. Built a box over the wheelwell to give the batteries a place to sit. Then installed both fuse blocks and connected the DC wires. Still have battery cables, positive buss and fuses to do. Also will be securing the batteries much more solidly and boxing them in. Looks like my passenger side fuse block pic is upside down, oops.
Where and how is this wheel well box attached to the metal of the van?
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Old 10-20-2018, 03:27 PM   #23
Midwestdrifter
 
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

I would suggest drilling through the floor or wheel well, and using a through bolt with large backing washer.

The strap may be able to handle 5klbs ( I doubt it though). It can't absorb and dissipate much energy in an accident, and the tight radius where it runs over the batteries would cut its breaking strength in half. Basically the strap layout you have would triple the point loading on the strap. So 150lbs time 10G times 3. For reference, seatbelts are rated at around 4k lbs pull out strength.

Adding a metal or heavy nylon strap around the side and bolted/rivnut to the wall would be a good addition. Replacing the wood screw and thin angle brackets with 1/8 steel or aluminum angle stock, and using #10 or 1/4" through bolts with backing washers, or using a good sized T-nut would also be a good improvement.
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Old 10-20-2018, 04:03 PM   #24
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Default 2016 144" 4x4 high bed MTB-carrier build

Quote:
Originally Posted by Midwestdrifter View Post
....
The strap may be able to handle 5klbs ( I doubt it though). It can't absorb and dissipate much energy in an accident, and the tight radius where it runs over the batteries would cut its breaking strength in half. Basically the strap layout you have would triple the point loading on the strap. So 150lbs time 10G times 3. For reference, seatbelts are rated at around 4k lbs pull out strength.
....
Adding a metal or heavy nylon strap around the side and bolted/rivnut to the wall would be a good addition.

I was thinking the webbing would do well at energy absorption. Assuming the side strap is added, my first approximation was that the batteries would shatter and come to rest inside the kitchen cabinet at 20G.

What about building a strong battery box with lid, strapping it to the wall, and rounding the edges of the box where the existing strap crosses?



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Last edited by Gski; 10-20-2018 at 04:08 PM.
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Old 10-20-2018, 04:53 PM   #25
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

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Originally Posted by Gski View Post
I was thinking the webbing would do well at energy absorption. Assuming the side strap is added, my first approximation was that the batteries would shatter and come to rest inside the kitchen cabinet at 20G.

What about building a strong battery box with lid, strapping it to the wall, and rounding the edges of the box where the existing strap crosses?



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Could be workable. In an off angle impact, the batteries will tend to rotate, and could come free of a single strap.
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Old 10-21-2018, 02:50 AM   #26
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

I appreciate your replies. I gave this a lot of thought today and have figured out what I think is a good solution. I’m going to pull off the temporary wood and L-brackets and make a 3-sided steel frame. There will be vertical steel angles on each battery corner with welded horizontals top and bottom. The 2 vertical angles near the inside of the garage will wrap around the battery corners and the 2 vertical angles against the wall will be oriented to have flats that can be screwed to the walls. The long bottom horizontal will be similarly flanged to screw into the top of the wheel well box where the L-brackets are now. This should give me a couple dozen screws into the wall panel/wheel well assembly. Then I can replace the ratchet strap with steel pieces front and rear bolted into the factory tie downs. I will post pics when I get it together.

The 3/4” thick wheel well box has about fifteen 2” screws run through the back of the wall panel into the box so it’s integral with the 1/2” plywood wall panel. The wall panel is attached to the van wall with sixteen 1/4-20 stainless machine screws into rivnuts.

Last edited by radair603; 10-21-2018 at 02:54 AM.
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Old 10-21-2018, 04:28 AM   #27
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

Look forward to pics because I canít really follow that.
I understand you built the wheel covers in place. Good.
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Old 10-21-2018, 01:29 PM   #28
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

I can visualize about half that. It sounds sturdy enough though.

When constructing cabinets that can be disassembled, I generally prefer L brackets and T nuts (with bolts) as they can be taken apart several times without detriment, and the connections are many times tougher than regular wood screws, as they will bend and absorb energy instead of pulling out and/or shearing.
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Old 10-24-2018, 02:12 AM   #29
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

Ratchet strap material or nylon webbing is not very dynamic and will definitely fail before stretching much at all. Sounds like you're on the right path. As an arborist, we use nylon webbing only in static loading situations, not dynamic loading situations.
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Old 10-25-2018, 07:56 PM   #30
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

Aren’t seat belts nylon webbing?
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