A box measuring 12" (W) x 10.25" (D) x 6" (H) was fabricated using 0.067" 5052 H32 Aluminum. The corners were welded and two lids were prepared, one solid and one transparent to allow for viewing.
DSC01603 View from the top showing the Aluminum control box with the plastic window installed. The bus bars will penetrate the left side and a cowling will be added over the terminals to prevent a shock hazard. There is plenty of room within the box to include a contactor, main fuse, shut off, USB port (for communication and programming), and support wiring, etc. High voltage power to B+ and B- will be brought in through the side of the box with shielded cables and a water tight gland. A 350 amp plug/connector will allow for connection to the test workbench or connection to the battery pack in the car.
DSC01605 end on view of the control box.
DSC01606 oblique view of the control box. The lid is secured with eight 4-40 screws that use PEM steel press-fit nuts for sheet metal (McMaster 95185A125 at $12.68 for 50)
DSC01607 closeup of the press fit female steel press-fit nuts that were used to secure the lids to the controller box. A shop press was used to insert the nuts. 4-40 is probably too small and in the next build a slightly larger bolt and press-fit nut will be used.
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