Quick update, work colleague got a 3d printer "for his kid" and offered to print us a new battery box.
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It is only 4mm PLA, so it isn't the strongest thing in the world, but I have heard that it possible to "heat treat" it to improve the layer bonding which improve the strength (by a lot apparently).

Also in the progress of ordering the Hardox armour and hammer from K-cut.

I might get this bot done before the end of this century. =P