I decided to rebuild the front battery box. I had it made from 1.3mm inox steel. At first i got only a box dimensioned to fit into the front of the Mazda car.
Then i had to taper the sides according to the shape of the boot. I marked points to drill holes from the bottom and also marked holes for the cable fittings from the sides.
It seems i can fit only 3 of the MEB modules into this box.
Idea is to fit 3 MEB blocks onto alu plate and support this plate bolted into the box
I prepared supports and drilled the holes to connect everything into the alu plate
I tried to fit two modules on the lower side
I used the empty space on the left to fit rubber standoffs that hold main HV cable terminals and a fuse. This can be used to separate rear and front packs for maintenance.
I tried to draw some patterns that would allow for simple liquid cooling installation with two channels fow waterflow, inlet and outled 10mm dia. How to seal the planar? Well i am thinking of simple use of Sika sealant on the surfaces outboard of the channels, maybe on the inboard too. In the case i couldnt get it sealed i would get the plates to a mill and made a O-ring channels along the outside edges.
Again i had to chamfer the edges of alu plate so that i could route BMS cables from the lower modules to the top. The end result with BMS modules connected looks like this:
I used CAN twisted pair from the rear battery box for communication between modules and left open connector for eventual connection with BMS VCU. My plan is to test main VCU for processing CAN and then decide if i can use main VCU or i need to use dedicated BMS VCU to communicate with BMS modules in the car. The existing 500kbaud CAN lines proves to be a bit crowded at the moment.