Weight is definitely an issue and going with the nimh would be counter productive on that issue. I did order some 6061 aluminum channel. The channel is 47mm wide, while the battery is 34mm wide. I'm considering using the 2100HV cells to make my packs. Although they are a bit thicker than what maxamps usually uses to make car packs, they are also considerably shorter and narrower. This would allow me to protect the packs with some sort of dense foam on three sides. I don't think that I'll want to completely encase the packs. I want to be able to visually inspect them.

Where can I get lexan and/or carbon fiber. I've heard that carbon fiber is really easy to work with and tha CA bonds it like concrete.