Build History (2) Note the sequence goes from bottom to top.

 The Tesla motor was put back into the car, but I had a concern that the motor is particularly heavy on the rotor side so a stiffening beam, that will be under compression, is being made to support the weight in addition to the frame that is located above the motor where it will hang. Hopefully this will be completed next week, and photos will indicate the modification.
It is necessary to secure the wiring harness to the glass fiber body in some places. My solution is as follows:-
I had CadCut, who cut my battery boxes, make about 50 hexagonal pieces out of 4mm aluminum. Hexagons as they are economic to cut and they don't rotate under the glass. Each had a 3mm hole in the center that I eventually drilled and tapped to suit a 4mm thread.
I then taped over the pieces some silver tape, that can be purchased from any good glass fiber supply. The reason for this is that the tape will prevent resin egressing into the tapped hole.
The Hexagons were then glassed onto the body work. Using a counter sunk drill the glass was pierced allowing the 4mm screw to secure either the Deautch plug attachments or tie clips.
Yes the whole area will be cleaned up.  

 The battery boxes for the rear of the car are virtually finished with the help of my friend Sid, who is a first class welder. I certainly learnt that drawing up components in a 2D sketch does not guarantee that they fit into a 3D car, but with a little modification the boxes were moved into position.
The battery beams were finished and square bolts inserted into each end. They are a tight fit and with a hard tap on the end with a cold chisel they were secured. I obtained my nuts from Bolt & Nut Australia, who had my goods delivered within a few days of order.
It was necessary to file a little inside the beams to make the nuts fit.
The right hand photo shows the bottom battery box in place, but not secured yet.
I expect some batteries to be installed and wired within a couple of weeks. 

I have combined two weeks of work in one session as I felt that I had not done much work, and was too busy on the weekend to write a report, but looking back it looks as if some progress has been made. Firstly I have virtually finished completing the steel beams that hold the batteries down in the battery boxes. Critically the beams need to be covered in glass fiber to insulate them from possible electrical shorts. In addition as High Voltage wiring are required to be Orange, I will go the whole hog and paint high voltage components as well. Well not the motor. A note in applying the glass, tack the glass into place first, then when the resin has cured wrap it. I then coded with a layer of epoxy (as it is less viscose than polyester, and leaves a nice smooth surface. A final coat of orange will then take place.

A lot of time was spent on installing the Air-Conditioning. I drilled the two holes in the underside of the  demister as per the photo in the instruction manual, only to find that some beams of the chassis interfered , so the holes were glassed up and new pipe manifold positions found, drilled and manifolds re fitted. Getting the air-conditioning unit in the right place required it to be located, marked, removed, drilled and and and and. I think it must have been put in and out of position about 6 times.

The break lines were removed and marked for new ones to be made, as battery boxes will be fitted in the sills where they are located.
The Anti-Theft device was purchased and arrived.

Finally the battery boxes and battery contacts arrived from CadCut in Wangara. It has taken some time but the present economic climate everybody appears to be very busy. Hopefully next week I will see some good progress with my friend Sid able to help me with aluminum welding of the boxes and the seat rails.

 Although this is a few weeks after week 2 it is because we went away in the Motor Home for a couple of weeks, resting after running Ping-Pong-A-Thon, a charity event we are involved with. We support charities that fight against slavery, watch this.
I have continued to work on the installation of the MoTeC display, as with all fiber glass jobs it can take time, with one piece being glassed into place, then wait for it to dry firmly before proceeding to the next step. I should be finished next week.
I came to the realisation that guaranteeing, when the car is finished I will have all the knobs and switches installed, and in the correct location is not a guarantee. For example I could get to the point when all is done that the switch to alter the climate's fan is not installed. My solution is to make a menu in the MoTeC that all functions can be located and added and modified.
Landsdale wreckers sold me a Lexus seat $100 so I could strip out the seat rails. Hours of grinding took place to get rid of the excess metal work. You have to remember that the seats need to be as close to the floor as possible, other wise my head will rub against the roof.
The drive shaft stumps arrived, very promptly, see video. I thought they were a bit expensive, like the Hylux headlights I bought 2 pairs! Fortunately I already have a buyer for the extras.
Now the Exciting bit. Time from EV Works came on the 30th and ran the Tesla Motor. Much delight as I was always concerned that the EBay purchased motor may not work.