Fat-fendered Ford battery tray

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 ==How to build it==
-Begin by taking a small cardboard box much the same size as the battery you'll be using. A cardboard mock-up is easier to handle than a regular 40-pound acid-filled battery. A box an inch or so larger will give you additional clearances for cables and hold-downs. Place the box against the frame area and try to imagine what kind of bracket required to hold it there. You can use duct tape to secure the box in place while you play with flexible steel strapping (usually found on packing crates) that you can shape into 90 degree bends to hold up the box (battery).
+Begin by making a small cardboard box, approimately the size of the battery you'll be using. A cardboard mock-up is easier to handle than a regular 40-pound acid-filled battery. Making it an inch or so larger will give you additional clearances for cables and hold-downs.
-The location should be a place where you can access the battery for servicing or removal; a place where potential damage from flying debris, i.e. stones and such, is at a minimum. An accessory shield can be added to further protect the battery casing. Ideally, the frame of the vehicle should be close to this location as it is one of the strongest mounting points available.
+Place the box against the frame area and try to imagine what kind of bracket will be required to hold it there. Duct tape can secure the box in place while flexible steel strapping (usually found on packing crates) can be shaped into 90 degree bends to support the battery.
-"What about water and dampness?" you ask. Well, most modern batteries are sealed, maintainance-free units, 99 percent impervious to outside water sources. Cable connections should be coated with dielectric grease to seal out corrosion. In addition, you can put your battery in a plastic marine battery case, which will provide both waterproofing and protection from mechanical damage.
+The location should be a place where you can access the battery for servicing or removal and where potential damage from flying debris, i.e. stones and such, is at a minimum. An accessory shield can be added to further protect the battery casing. Ideally, the frame of the vehicle should be close to this location as it is one of the strongest mounting points available.
-A plastic marine battery case can also be used instead of the cardboard box to find your location.
+"What about water and dampness?" you ask. Well, most modern batteries are sealed, maintainance-free units, 99 percent impervious to outside water sources and cable connections can be coated with dielectric grease to seal out corrosion. In addition, you can put your battery in a plastic marine battery case, which will provide both waterproofing and protection from physical damage.
-You can use cardboard to form a tray to hold the battery and, by making a 90 degree bend in the cardboard, you can run it up along side of the frame and use the frame to stabilize and mount the tray. You can use nuts, washers, brackets...etc to extend out from the frame, giving the tray a solid mounting surface.
+A plastic marine battery case can be used in place of the cardboard box to find your location.
+You can use cardboard to help design a battery tray and, by making a 90 degree bend in the cardboard, you can run it up along side of the frame. Use the frame to stabilize and mount the tray. Nuts, washers, brackets...etc can extend out from the frame, giving the tray a solid mounting surface.
 To utilize the vertical side of the tray, a cutout can be made and bent 45 degree outward, adding a hole for a mounting bolt to create an offset for a mounting location to the frame. If laid out correctly, all three sides plus the bottom can be cut out of one piece of flat stock and bent to form the final battery tray. See pictures.

Fat-fendered Ford battery tray

Revision as of 23:47, 10 February 2010

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