Two quick comments.
Some EV people have used pre-made fiberglass angle material from fiberglass
ladder manufacturers in place of the traditional angle iron for battery "boxes".
The advantage is light weight, easy to cut / work with and no rust issues. I
don't know about long term durability. This fiberglass angle (90 degrees and red
in color) juts out two to three inches and is ~1/4" thick (surprisingly strong
and stiff). I have seen some nice EVs using it at the top and bottoms of the
batteries. Appears to work real well and doesn't look home made. I don't have a
source or a price yet. Don't know what I am talking about? Go to Home Depot etc.
and look at the 14' plus fiberglass extension ladders. In terms of the corners a
simple 45 degree cut like on your wood door trim at home makes it all look nice.
Add a little epoxy, to each corner plus additional fiberglass material (aka boat
repair materials) and you are good to go around a corner for the
frame.
Point 2 - remember that while Carbon Fiber can be stronger than Fiberglass
it also conducts electricity just like angle iron would without a surface
coating. Danger Danger Buck Rogers.
Mike
Bachand
Denver Electric Vehicle Council (DEVC)
Kawasaki Ninja
EV