Since the last post I finished connecting the rear battery rack to the vehicle. Most of the rack is connected by 3/8" bolts and locking nuts directly through the sheet metal. Here's a picture of the bolt through the top.
And here's the bolt, washer, lock washer, and nut on the underside.
This arrangement worked great for the majority of the rack. There were a few places where the rack needed to be connected but was not accessible from under the vehicle.
This is where the rivnuts come in. Rivnuts are blind rivets that accept a bolt. You drill a hole, place the rivnut through the hole, then compress the rivnut around the sheet metal.
This is a picture of an uncompressed (right) and compressed (left) rivnut.
You can see that when compressed the rivnut forms a collar. This collar traps the sheet metal and secures the rivnut. The inside of the rivnut is threaded and accepts the 3/8" bolt.
In case your wondering about the strength of the rivnuts they were originally developed for holding airplanes together!
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