Our team has recently started the process of cutting a hole in the car where the spare tire once was, to make room for two battery racks. We first tested the measuring and cuts on an older Mustang before cutting into our project Mustang. The tests were very successful, so we moved onto our project car. Pilot holes were first drilled into the corners of the planned hole, to make the cutting easier. We then used a grinder to make the first cuts in the thin sheet metal. After the first cuts were made, a plasma cutter was used to make the final cuts and clean up any excess metal. After the hole was cut, the battery racks fit snugly into the hole. The racks will later be secured to the sub-frame of the car to prevent them from moving.
Mr. Butler, Hunter Foulks, Spencer Griffin, and Jesse Gilbert debate on how to install the front battery rack.
Mr. Butler, Hunter Foulks, Eli Strickland, and Jesse Gilbert test the fit of the rear battery racks in our older Mustang.
The test cut made on our team's older Mustang.
Mr. Butler uses a plasma cutter to make final cuts and trim off excess metal.
Spencer Griffin trimming off excess metal and smoothing any sharp edges.
First battery rack installed into the project car.
Spencer Griffin and Mr. Butler measure the hole to install the next battery rack.
