It may seems a bit early in the trike’s progress to by mounting electrical components, but the controllers not only pose a size factor, they must also be positioned so that all the wire harnesses will reach, they can be properly protected from the elements and they will not interfere with any of the other main components of the trike yet to be fabricated. The controllers will be positioned just above the battery box and will be covered by the deck lid which will be constructed later.
Two support bars are cut from 1x2x.090 rectangular tubing and they are bolted in the battery box so that they are removable (see arrows in Photo 1) The bars serve a dual purpose. First, they lock in the batteries so they can not come loose in the event of an accident. And second, they provide mounting support for the controllers/heat sinks as well as other electrical components which will be located under the rear deck lid.
Brackets to mount the heat sinks to the bars are cut from 1 1/4″ angle iron. (Photo 2)
The brackets are bolted to the pre drilled holes in the heat sink. (Photo 3)
The heat sink with brackets bolted on is then positioned and clamped in place so that the mounting brackets can be tack welded to the outer perimeter of the battery box and to the inner support bar. (See arrows in Photo 4 showing the heat sink brackets welded in place)
The heat sinks are temporarily bolted in place. (Photos 5 and 6)