At some point you will need to either weld or get some
welding done. We were fortunate enough to have an
interested high school teacher who took part in our project
who let us use the welder at the school. Cultivate friends or
make the acquaintance of a quality weld shop in your area.
Learning how to weld is a skill that most people can learn if
they want to. It takes a bit of time but you can do it, or find
some friends with a welder.
You can, of course bolt everything together if you want. But
for real smooth fabrication of battery holders and other parts
welding is preferred.
Although this is an expense it is by far not the most
expensive part so don’t sweat a few bucks spent having
someone else do some work for you.
Forget trying to use any welder that works with 110 volts of
electricity. These smaller units will not work for welding the
heavy duty frames you need for your batteries.
An electric arc welder, or mig welder of at least 220 volts is
needed to do the work. It will need to produce at least 100
amps of power output. This will easily weld the material you
will be using.
If it has been a while since you have welded anything or you
are a complete novice, there are some serious safety
considerations in welding. You are dealing with metal that is
hot enough to melt.
Does that sound dangerous? Well, it can be, as any
experienced welder will tell you. Be careful or ask for help.
You will be amazed at how many people will volunteer.