Tuesday, March 01, 2011

Drilled and Attached Battery Box Doors

Tonight I continued working on the battery box doors.

I measured where I could drill holes into the doors, and still hit the door holders beneath. 1/4" looks to be the spot.

I measured and marked the spots on the doors to drill.

I placed the doors back onto the boxes, and using a #39 drill bit (slightly smaller than the #4-40 machine screws I'm using to attach the doors), I drilled through the door and the holder underneath it.

Next, I widened each hole on the doors to be just wide enough for a #4-40 screw to slide through, using a #35 drill bit.

I then countersunk each hole on the doors.

Finally, I used the screws to self-tap the threads in the door holder holes.

Two happy doors held on by eight happy 3/8" #4-40 screws.

I considered attaching the battery boxes to the foot shells, but I'm going to wait a little bit. The location of the screws is affected by the drivetrain, which is incomplete (no motor mounts). I could just go ahead and pick convenient spots for the screws now and relocate them later if necessary, so we'll see.


Anonymous said...
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DarthMoose74 said...

Hey Victor, I am getting ready to do my battery boxes and was wondering if there is any listed measurements for the door opening size anywhere?

Thanks for any help in advance!

Droid #2 is looking great by the way. :)

Victor Franco said...

Hi Moose,

The doors are 5" square, and centered on the inboard side of the foot shell.

Thanks for the compliment on droid #2. :-)