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titleMaterial strength of Acrylic (Plexiglas), PETG 3D printed plastics.

[1] Acrylic
Yield Strength: 64.8 - 83.4 MPa (Average value: 75.4 MPa)
Young’s Modulus: 2.76 - 3.30 GPa

Flexural Modulus: 2.96 - 3.30 GPa
Flexural Yield Strength: 98.0 - 125 MPa (Average value: 109 MPa)

[2] PETG
Yield Strength: 28.3 - 58.6 MPa
Young’s Modulus: 1.10 - 20.3 GPa (Average value of 2.65 GPa)

Flexural Modulus: 1.17 - 2.76 GPa
Flexural Yield Strength: 39.2 - 88.9 MPa (Average value of 69.5 MPa)

In short, Plexiglas is a strong enough viable alternative for the side walls of the cover.

Gel-coat
Protective finishing layer for composite surfaces.
Leaves a hard smooth surface good for sticking on adhesive.
Requires sanding and buffing for a smooth surface.
If painting the cover, apply gel-coat first then paint over it.

Source:
[1] http://www.matweb.com/search/datasheet.aspx?bassnum=O1303
[2] http://www.matweb.com/search/datasheet.aspx?matguid=4de1c85bb946406a86c52b688e3810d0

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titleWaterproofing

Gasket for battery cover would be stamped out or cut out from a flat sheet of rubber to match the outline of where the cover would sit on the edges of the walls.
Neoprene is what is typically used for gaskets (synthetic rubber).


Gaskets could be manufactured by using die cutting, water-jet cutting, and laser-jet cutting.
Manufacturing could be potentially done in-house with a large enough laser cutter and a large sheet of rubber, or could potentially be made using a small blade slicing the rubber to the CADed shape.


For the seal to be effective, it should be one continuous piece that covers all openings and shall be compressed against the surface of the resting site and the cover so that small air gaps could be filled to prevent potential water from leaking.

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Assembly Detailing

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titleFiberglass and resin cost

Total surface area: 5.19m^2
Required area of cloth: 23m^2 (2 layers each side plus 10% for mistakes)

Image Added

Widest part of cover: 0.7112m