After building a PVC pipe battery holder for my electric bike, I used a vacuum form machine to make a polystyrene battery cover. I built up a cheap tool form using cardboard (which turned out to be too week, but it was quick).

As the vacuum was forming the polystyrene around the cardboard the box started to deform so I had to release the vacuum before the styrene had fully formed itself to the PVC pipes, but it got close enough to be screw mounted. Continue reading →