![](http://3.bp.blogspot.com/_m91aiCJDbnU/SNRYIE84JiI/AAAAAAAABKM/IJONVw2Xeqo/s320/01_SeatBoxFlat.jpg)
As with the sheet metal for the lower rear battery box, I printed it out on several sheets of 8.5x11 paper, taped it together and cut it out (the holes in the middle are extra taping points):
![](http://1.bp.blogspot.com/_m91aiCJDbnU/SNRYIE8C-cI/AAAAAAAABKU/Jt75QqBPAEI/s320/02_PattCut.jpg)
Since I was making two identical boxes, I just clamped two sheets together and taped the pattern on top of the stack:
![](http://1.bp.blogspot.com/_m91aiCJDbnU/SNRYIZANS1I/AAAAAAAABKc/TXpE3sJevaw/s320/03_PattMetal.jpg)
Here is one of them, cut out and sanded down all pretty:
![](http://3.bp.blogspot.com/_m91aiCJDbnU/SNRYIrbGpTI/AAAAAAAABKk/zcJ-Z4ueZVs/s320/04_ShinyCut.jpg)
The folds are kind of tricky. If I had sheet metal wider than 24" I would not have done the pattern this way - but this is the only way it would fit on a 24x48 sheet of steel. First, I folded the upper lip over (to make a sturdy and non-sharp edge around the top). Next, I folded the "envelope flaps" partly over:
![](http://3.bp.blogspot.com/_m91aiCJDbnU/SNRYIv7-DRI/AAAAAAAABKs/uR3uUhdvvtE/s320/05_FirstFolds.jpg)
More folding. Here comes the tricky part - you need to fold it all up just about simultaneously or it does not mesh properly. Even as it meshes properly, there is some final hammering / pushing / bending needed to get it into box shape:
![](http://3.bp.blogspot.com/_m91aiCJDbnU/SNRX9M_AJWI/AAAAAAAABJk/bSJqWZs8OZA/s320/06_SecondFolds.jpg)
Here it is, completely folded and ready for welding:
![](http://4.bp.blogspot.com/_m91aiCJDbnU/SNRX9SrkWWI/AAAAAAAABJs/rOQCJZS5PxQ/s320/07_Folded.jpg)
To weld, I first used various clamps to keep the flaps down completely flat against the walls:
![](http://4.bp.blogspot.com/_m91aiCJDbnU/SNRX9lOjMuI/AAAAAAAABJ0/q1GwrcR84g8/s320/08_Welding.jpg)
Here is KatC, spot-welding one of the boxes:
![](http://2.bp.blogspot.com/_m91aiCJDbnU/SNRX9v6lrVI/AAAAAAAABJ8/NItL8eQmseA/s320/09_Welding.jpg)
Given that this will have a complete rack supporting it, spot-welds are more than adequate. I will paint these and then put seam sealer around the edges to keep water out:
![](http://1.bp.blogspot.com/_m91aiCJDbnU/SNRX9xMnYhI/AAAAAAAABKE/6P9j5g4ha14/s320/10_Complete.jpg)
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