I am converting my '04 Prius via the CalCars PriusPlus method.
Photos from Chris Ewert's Conversion
Cutting the aluminum with a hacksaw
All the pieces necessary for the battery trays
All the parts from the tray laid out
Battery tray just set together
Close up of the battery tray just set together
Tray set together, ready for creating "jig"
Starting to assemble the jig
Getting the jig assembled
Dremel drill press used for drilling holes in angle irons
Holes drilled in the aluminum, then countersunk
Sample corner finished (done on scrap aluminum)
Shows the self threading screws sticking out
All 4 finished trays laid out like they will be
Experimenting with the support angle irons
Starting on the top of the battery box
45 degree angles cut in angle irons
Corner bracket just set on the top
3 angle irons cut and just sitting on the box
Shows the Plexiglass "shield" on the inside of the angle irons
Partially assembled battery box - bolted on top, but not the sides
Inside of the corner of the battery box top
Binding posts that I choose to use. They worked, but they aren't part of the official conversion method
A completed corner, bolts in and have been ground off.
Shows the angle iron that will be used to bolt down the top
Mostly finished battery box. Still lacking the bolts in the center of the pack, holes for bolting the top down and holes in the frame
Bottom of the fuse holder (for DIN rail mounting)
The Kilovac EV200 contactor
Battery Box sitting on steel tube
Battery box sitting on steel tube with second tube for screw lift support
Alt mounting method: modified hanger bolted into battery box mount
Alt mounting method: Test fit of unfinished battery box top in forward location
Welded support connected to support angle irons
Welded support connected to support angle irons
Right side battery box supports
Left side battery box supports
Rubber pad under support angle irons
Entire battery box mounting supports
Electronics box being assembled
Mostly completed electronics box
Mostly completed electronics box
Installed electronics box and charger
Installed electronics box with top on
Close up of HVD1 installed
Close up of contactors installed
Left side of electronics box
Right side of electronics box
Close up of fuses in electronics box
Close up of ZiVan NG3 charger
Unstuffed control board - front
Unstuffed control board - back
Batteries being installed
Battery box top (modified for alt. mounting)
Bolt on top of OEM battery
Removing carpeting from on top of OEM battery
Removing the upright part of the rear seat
Opening the OEM battery lid
Inside the OEM battery (unmodified) from rear of car
Inside the OEM battery after HV tie-in
Unmodified OEM battery low voltage wiring
Modified OEM battery low voltage wiring (for charge interlock)