Electric vehicle battery enclosures and methods of assembling electric vehicle battery enclosures involve a base portion to hold one or more batteries that provide motive power to an all-electric or hybrid electric vehicle. An electric vehicle battery enclosure includes a cover portion to mate with the base portion to enclose the one or more batteries, and a sealant to create a bond between the base portion and the cover portion around an entire perimeter of the enclosure and to seal the enclosure based on a uniform height of the sealant around the perimeter of the enclosure.