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Safari Helicopter Construction
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Date:  7-8-2006
Number of Hours:  3.25
Manual Reference:  N/A
Brief Description:  Battery Box

Since I'm moving the battery from under the copilots seat to under the instrument pod, I had to make a support shelf the hold it. Photo #1 shows the brackets that support each side. I used .063" 6061 alum. I actually had to make these twice. The first attempt resulted in total seperation along the forming line. It is very important to heed the minimum bend radius guidelines when trying to form 90 degree bends in thicker sheet material. I had previously black anodized the factory supplied mounting box, and decided to incorporate it into the new design. The clevis fitting in photo #3 is made from 7075 and will connect to a support rod attached to the lower frame between the pedals.The completed box is actually quite strong and should be more than adequate to support the weight of the battery. It may even help to dampen the vibrations transmitted thru the upright pod support tubes.
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Support brackets

Support brackets

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Trial fit

Trial fit

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Assembly detail

Assembly detail

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