To enclose the batteries inside the bodywork, I needed some type of framework to which I could attach the "skin". Some 1/2" conduit would work, but would be heavier than necessary to simply support the body panels. I chose instead to use something a little unconventional. At the local auto parts store I picked up two 6 ft. pieces of 3/8" steel fuel line tubing. It's extremely light, easy to bend, can be welded, and it's hollow so I can drill it for pop-rivets.;)
I bent the 3/8" fuel line to the same shape as the outer bottom rails and cut them to the same approximate length plus about 1 1/2" on each end. I used the leftover pieces to cut a pair of uprights for each side. The front pieces are sized so that, measured from the bottom of the battery tray, they are 9" tall (the overall height of the batteries with terminals in place + 1/4"). The rear ones are 3/8" taller simply to give the finished side pods a little tapered appearance.:cool:
Using a cadre of measuring tools and a lot of "calibrated eyeball", I located and welded the vetical pieces in place. Then, using some masking tape to help me hold the top tubes in place, I trimmed and fit the ends. Once satisfied with the overall fit, I welded them solidly in place.:3dSMILE: