Decided to document my conversion in the hopes it will help someone in the future.
I have a 72 volt 2002 Ford Think that I’m installing three 16s Chevy Spark batteries into. Chevy Volt batteries are similar. Gem’s are also very similar to the Ford Think except for battery placement.
First I decided to remove the cooling system elbow, hoses and brackets to trim down the size. I removed the four nuts and four long bolts and took the brackets and hoses off.
Next I pulled the end plate back a couple of inches so I could sneak out the coolant elbows.
I had to stand the packs on end and stand on them with one foot while reinstalling the bolts. The pack separates a little when the bolts are removed.
Now the packs were trimmed down enough where I would have plenty of room to make them fit into the battery tray. Picture showing one pack done and one not yet.
Good news is the coolant nuts fit the battery pack posts if your packs didn’t come with the nuts