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.