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  #1  
Old 11-19-2010
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WestySKPs WestySKPs is offline
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Default Battery tray and cable rework winter project

Hi All,

We pulled our batteries out to rebuild/replace the tray. As expected, we found plenty of rust. A couple of pics attached of the setup and tray.
The NAPA 8240N's are all about a year old, so haven't decided on whether we will replace them now or not. Because of the added width of their plastic handles, the batteries sit a bit staggered, not flat.

The existing cables have a couple of spots where the positive and neg are a little too close together (pic). Cables are defintely going to be replaced/rerouted. I haven't decided whether I am going to make them myself or have them built. Is it OK to daisy-chain the cables or does this create other issues?

I am going to try and get the pan fabricated locally. What is the best/preferred material? Any trick to remove the old pan (I counted four mounting bolts)?

We are jumping in on this one. Batteries, and their contents, kind of give me the heebeegeebees. Lets just call it "exposure therapy". Many more questions to come. Sure wish I had taken more pictures at RATS.

Thanks for the help,

MnM
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Old 11-19-2010
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Since it is your money, I think stainless steel would be best. Line it with a non-conducting acid proof material and be sure there are drain holes to let moisture out. When you wash of the batteries periodicaly you want that stuff to go somewhere, but not drain down on something important.
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Old 11-19-2010
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Greetings, MnM:
how solid is the existing tray? If there is still plenty of steel left, I would use an angle grinder with a hefty wire brush to clean it up. Drill some drain holes as Gardner says. Then, I would use some 3M rustproofing to "paint" it with. I did that with our battery box and have been very happy with the results. Probably any of the heavy duty rustproofing would work. It stays a bit flexible so it is less prone to chipping at the edges.
As to new cables, Shane and Tom Warner and I have crimpers for heavy cable. I would suggest making your own. That way, if one of the dimensions is off a bit you can make some adjustments. I replaced my battery cables with 4/0 welding cable. A good source for the cable ends is
(www.genuinedealz.com). They have a good selection of types and sizes of cable ends. So far the whole thing has worked very well. You can use my crimper if you want, it will handle up to 4/0 cable.
good luck with the project.
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Old 11-19-2010
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If it is rusted try baking soda and water make a paste, and neutralize the acid. Rinse with lots of water.
use a wheel or grinding wheel to cut the plastic ears off of the batteries, then use temporary carry handles that attach to the posts to lift the batteries. THey are heavy but not for the young & strong
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Old 11-19-2010
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Quote:
Originally Posted by Bill Pape View Post
If it is rusted try baking soda and water make a paste, and neutralize the acid. Rinse with lots of water.
use a wheel or grinding wheel to cut the plastic ears off of the batteries, then use temporary carry handles that attach to the posts to lift the batteries. THey are heavy but not for the young & strong
I agree with Bill,i use a sawzall to remove the handles and there molded in bracket.
Your tray looks good,clean and reuse!
This is not a chevy battery box,this is heavy steel.
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  #6  
Old 11-19-2010
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Put some POR15 on the tray.
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Old 11-20-2010
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I think using the studs instead of the tapered battery posts is a good idea. It will make cable fabrication a whole lot easier and also give additional clearance as opposed to the bulky post clamps
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Old 11-20-2010
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Here are a couple of photos of the cables I made up for my FC when I had it…I will bring the crimping tool to Quartzsite if anyone wants to use it to make up some new cables while there!
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Old 11-20-2010
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Reuse the old tray but get it epoxy coated.
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Old 11-20-2010
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Quote:
Originally Posted by KCSS View Post
I think using the studs instead of the tapered battery posts is a good idea. It will make cable fabrication a whole lot easier and also give additional clearance as opposed to the bulky post clamps

I'm not a battery expect but i have "heard" that the lead post give more amps than the steel studs,if thats a concern.
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