How to DIY - add access holes for LVB 12v battery connection points & HV Disconnect Relay for Safety

[JM22681]

there is no after-market beauty cover with 3 access holes that I am aware of. I don't know about the '24 design.

takes 10 minutes with a 1-7/8" hole saw.

get 3x 2" 'plugs' (50mm) from the hardware store, and you are done...

Yep, Amazon is out of the 2" so I got the 2.5". Does same logic apply where the hole should be 1/8" smaller?

Sponsored

 

[dtbaker61]

Yep, Amazon is out of the 2" so I got the 2.5". Does same logic apply where the hole should be 1/8" smaller?

you can probably find 2" at your local hardware store. Or PM me with your address and $5 for postage, I have a bag of them.

 

[alangant]

Yep, Amazon is out of the 2" so I got the 2.5". Does same logic apply where the hole should be 1/8" smaller?

The 2.5" holes work great. There is a template for them in another thread.

 

[JM22681]

Yep, using it later today. Can you confirm 2 3/8 hole saw bit?

 

[alangant]

Yep, using it later today. Can you confirm 2 3/8 hole saw bit?

I cut 2.5" holes for my 2.5" plugs. And I had to bend the retention pieces in a bit with plyers to be able to remove them!

 

[Old_Norm]

These are extra battery access covers I 3D printed. The hole size would be 2.5 inches. If anyone wants them message me. Just pay postage from Columbus, OH.

 

[JM22681]

Followed this procedure today using the 2.5" template. Awesome guide and thanks for quick responses.

@Old_Norm I will gladly send you a few bucks for those!

 

[worachj]

I went to my local library and 3D printed a set for free.

https://www.thingiverse.com/thing:6165861

 

[Old_Norm]

Followed this procedure today using the 2.5" template. Awesome guide and thanks for quick responses.

@Old_Norm I will gladly send you a few bucks for those!

Sorry Jeff, They are gone.

 

[dtbaker61]

I went to my local library and 3D printed a set for free.

https://www.thingiverse.com/thing:6165861

Excellent, maybe we can get Ford or @AOSK to make a black -, red +, and orange with disconnect symbol for the HV disconnect ?

 

[AHoss75]

Followed this procedure today using the 2.5" template. Awesome guide and thanks for quick responses.

Hi, where can I find this template?

 

[AHoss75]

I went to my local library and 3D printed a set for free.

https://www.thingiverse.com/thing:6165861

Did you use the 2.5" template? if so, I'm assuming you had to make these larger to fit (these say they are 50mm which equals just about 2"). What size did you end up setting them to?

 

[worachj]

Hi, where can I find this template?


Did you use the 2.5" template? if so, I'm assuming you had to make these larger to fit (these say they are 50mm which equals just about 2"). What size did you end up setting them to?

I printed the 50mm size. Don't know where to find the 2.5 inch files.

I haven't drilled any holes as of yet. Still deciding if I want to spend the money to do FDRS updates.

 

[dtbaker61]

I printed the 50mm size. Don't know where to find the 2.5 inch files.

I haven't drilled any holes as of yet. Still deciding if I want to spend the money to do FDRS updates.

I don't use access points for FDRS.... I use the 12v for export to run little inverters, but have switched to using heavier cables for better connection anyway. I think some (easy) access to 12v is important to give/get a jump and or making it easy on the Dealership if and when they do a manual software update for you.

The THIRD hole, over the HV disconnect relay is probably more important, but less likely to ever be used. The location and access to this disconnect *should* be made obvious to first responders & tow truck drivers who most likely are untrained in where the 'cable cut point' is on the MME in case of accident where battery damage is suspected and they want to minimize chances of shorts/fires.

 

[JM22681]

Hi, where can I find this template?

The template for the holes is in this post here:

https://www.macheforum.com/site/thr...point-access-battery-access.10976/post-592027

Print it at 100% scale.

I don't have a template for the custom 3D printed hole covers if that's what you're asking.

Sponsored