Step 2: Dowels

  1. Take the two 1/2” square wood dowels. Cut each of them to 51.7 cm length; try to keep the cuts square.

  2. Spray paint each of them black. Let dry (you can work on the other steps while the dowels are drying).

  3. Take the battery assembly created previously. Press the headers soldered to the Power Distribution board (PDB) fully into the end of the dowel. Use the square drawing on the back for alignment with the dowel. You will need to use some force to push the headers into the wood; if necessary, use the spacer to make it easier to push. Repeat the same with the other dowel and power distribution board.

    Dowel with PDB

  4. Remove the PDB from the dowel. Mix some epoxy glue, apply it to the end of the dowel and replace the PDB seating it fully. Repeat with the second PDB and dowel. Be careful that no epoxy gets on the holes for wires.

  5. Cut two 12x12mm squares from the EVA foam. Use epoxy to glue it to the free end of each of the dowels. Leave for couple of hours to let the epoxy harden.

    Dowel with EVA foam square