View Single Post
Old 07-15-2012, 11:10 AM   #321 (permalink)
Daox
Administrator
 
Daox's Avatar
 
Join Date: Dec 2007
Location: Germantown, WI
Posts: 11,203

CM400E - '81 Honda CM400E
90 day: 51.49 mpg (US)

Daox's Grey Prius - '04 Toyota Prius
Team Toyota
90 day: 49.53 mpg (US)

Daox's Insight - '00 Honda Insight
90 day: 64.33 mpg (US)

Swarthy - '14 Mitsubishi Mirage DE
Mitsubishi
90 day: 56.69 mpg (US)

Daox's Volt - '13 Chevrolet Volt
Thanks: 2,501
Thanked 2,587 Times in 1,554 Posts
I worked on the Prius mounting setup yesterday.

I put the box in and marked where I needed to put the weld nuts in. Fortunately, on the driver's side that spot fell directly between the frame rails.





On the passenger's side I was also very close to the frame rail, within 1".





So, I drilled the holes for the weld nuts.





And then welded them up bit by bit with time to cool between so as not to burn too much paint and not melt the sealant that was fairly close to it.







A little grinding and a few coats of primer finished things off.





I am interested in suggestions on how to reinforce it a little. MrBigh is correct that the sheet metal is thin back there. I do think that it will be okay the way it is unless the trunk area gets smashed and there is a roll over in an accident. I was going to weld in some extra metal, but there is a lot of that sealant around the top and bottom (sorry no pics) that I'd like to avoid. There is also the issue of rust-proofing things after the fact (yay Wisconsin salty winters) that is probably going to be a problem. I was able to prime and paint the passenger side weld nuts, but since the driver's side are between the frame rail sides I can't actually get to them to do anything.

Attached Thumbnails
Click image for larger version

Name:	prius 006.JPG
Views:	301
Size:	62.5 KB
ID:	11164   Click image for larger version

Name:	prius 008.JPG
Views:	306
Size:	57.8 KB
ID:	11165   Click image for larger version

Name:	prius 010.JPG
Views:	289
Size:	62.4 KB
ID:	11166   Click image for larger version

Name:	prius 013.JPG
Views:	274
Size:	60.0 KB
ID:	11167   Click image for larger version

Name:	prius 016.JPG
Views:	288
Size:	65.1 KB
ID:	11168  

Click image for larger version

Name:	prius 018.JPG
Views:	261
Size:	53.4 KB
ID:	11169  
__________________
Current project: A better alternator delete
  Reply With Quote