Quick-disconnect rear mount battery
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| − | + | ==Things you'll need== | |
| + | *[[Battery tray with hold down]] | ||
| + | *Disconnect switch | ||
| + | *Free formed project box | ||
| + | *Ford solenoid | ||
| + | *Gun cleaning handle | ||
| + | *8-32 thread stud | ||
| + | *3/16 brass compression ferrules (2 pcs. needed) | ||
| + | *Acorn nut or nylok nut | ||
| + | *900 to 1050 amp battery | ||
| + | *Battery cable (1 ga or 00 ga) | ||
| + | *Assorted cables, wires, grommets and hardware | ||
| + | |||
| + | ==What we're going to build== | ||
| + | {| | ||
| + | |[[Image:Front_face2.jpg|thumb|365px|Front view]] | ||
| + | |[[File:Rear2.jpg|thumb|350px|Rear view]] | ||
| + | |} | ||
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| + | Now that you have a mental picture of what it's going to look like, together with the list of parts required, this should be an easy task to do in one evening in the shop. | ||
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| + | ==Building== | ||
| + | Let's begin with the layout and selection of battery size. The bottom hold down plate size will be determined by the size of battery that you want to use for your application. Start with a clean piece of cardboard laid on the bench or garage floor. If you have the battery you want to use, place it on the card board and allow a border of 1 1/4 inch around three sides of the battery to serve as the rolled up rim around the battery case. With a marking pen and a ruler draw a line around the battery. | ||
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| + | Take your disconnect switch and the Ford solenoid and lay them down on the cardboard to get an idea of the space required and the layout. Use a gasket punch to make a hole for the disconnect switch to go through and use a prick punch to mark the hole centers of the bracket on the solenoid. | ||
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| + | Your layout should look like an uppercase letter "L" (see layout picture). Leave enough room around the switch and solenoid to form a box around them for stiffness and strength. Essentially, you want to have a good solid mounting base for the battery and switch cluster. You can modify this layout as needed for your application. | ||
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| + | When you have your design roughed out on the cardboard, cut and slice the card board, bend it to the shape of the finished product. Use tape to hold it in place and tweak as required until you are satisfied. | ||
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| + | Get a piece of 24" X 24" by 1/8" steel or 5/16" aluminum plate. Place the template you made above on the plate and using a center punch, punch each inside and outside corner and draw your connecting lines. Mark the holes for the switch, solenoid, and battery hold downs and drill those first. Those punch marks and lines will be used for you to line up the brake that will bend them. If you don't have a brake, you can always have the local sheet metal shop bend them for you. Weld in extra gusset plates for strength, then weld and grind the corners. Mount the assembly to the floor of the trunk in a level area. Install battery. | ||
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