Off Road Teardrop Build: Trailer Build - Week Eighteen

Now that most of the wiring is coming to a close, its time to get the battery compartment started. I welded the tongue frame up back a couple months ago, so I need to cut the front sides and make the lid. I purchase another sheet of 3/4" plywood to get the box going. the box is 2 foot tall with a 1 foot radius on the top. I also contoured the bottom to follow the 9 inch radius of the main trailer to give it a nice finish from the profile.

Battery Box Sides Cut and Fitted Up to Curve

Front View with Battery and Inverter / Distribution Panel Set for Height Check

Front Panel Set

Closeup of Battery Box at Curve

With the battery box frame wended to the trailer tongue, I noticed the tongue flexes slightly. I decided to keep the box independent from the trailer and cut the box so I would have a 1/2 inch gap between the main cab and the battery box. I will cover the gap with trim so the box can float behind the trim while the tongue flexes.

Profile of Battery Box

Don't throw your scrap pieces out until your finished with the trailer. All these leftovers can be used for more part or piece as you get to the finish details.

Curved Ribs for Battery Box Lid Cut from Scrap

Battery Box Lid Assembled and Positioned

1/4 Inch Spacer Needed for Hurricane Hinge

1/2 Inch Spacer at Bottom for Gasket and Aluminum Trim

Frame Glued Up for Interior Skin

Clamping of Skin to Frame

Checking for Gaps and Skin Alignment

Add Balance of the Clamps for Full Skin Contact

Let the Glue Set

While the glue is setting on the battery box, I proceeded to measure out the spar bracing pieces I cut back when the side panels were cut. These curved pieces will be cut where ever there is a spar to brace between spars and it also provides a wider surface to attach the exterior skin and a place to screw into with the finish trim on top.