Procedure
Install the lithium iron phosphate (LiFePO4) battery pack in custom steel enclosures. LiFePO4 is strongly recommended for its thermal stability and safety. Enclosures must provide structural protection and crash resistance.
- Design battery enclosures based on available space in engine bay and trunk
- Fabricate steel battery boxes from 3mm sheet ā weld seams fully
- Line battery boxes with 12mm closed-cell foam for vibration damping
- Install LiFePO4 battery modules into boxes
- Connect cells in series using nickel-plated copper busbars
- Install cell-level fusing on each module
- Wire Battery Management System (BMS) to each cell group
- Install Main Service Disconnect (MSD) ā clearly labelled emergency orange
- Mount battery boxes ā bolt to reinforced subframe
- Install isolation monitoring device (IMD) for ground fault detection
- Route HV cables in orange conduit per EVSA standards
- Insulation test: must read >1 MĪ© HV to chassis
Safety Warnings
DANGER: Battery pack voltage may exceed 400v – LETHAL
- Always work with pack disconnected at the MSD
- Use 1000V- rated insulating gloves at all times
- Keep a Class D fire extinguisher nearby
- Do not smoke, create sparks, or use open flames
Pro tip
LiFeP04 chemistry is strongly recommended over NMC for classic car conversions. At 3.2V nominal per cell, a 96S configuration gives approximately 307V – ideal for 200V to 400v motors.