Lightweight battery swap and box

[tharptroy]

There were a few things I wanted to get out of this:

1. I wanted to get a lightweight dry cell battery to reduce the weight of the vehicle.
2. I wanted to have the room to construct an airbox for my intake (not done in photos).
3. I also wanted this weight of the battery to be shifted downward, closer to the plane on which the center of mass (for the vehicle) lies. (or below it if possible).

fordfasterr (EXD member) was the first to have this particular battery in an XD, and so I opted to use the same one he had chosen.

This was an Odessy brand PC 680 battery.

I bought mine from www.batterymart.com and received the product in good condition and in a timely fashion.
direct link to battery as of 2/2/05
http://www.batterymart.com/battery.mv?p=ODY-PC680

I decided where I wanted to mount the battery...Immediately next to the stock location, hanging from where the OEM battery once rested.

Here was my logic for this choice:
1: Minimal wiring modifications
2: Meets all pre-defined criteria
3: Keeps a little weight up at the front wheels on the driver side...which isnt bad, since the cast Iron block of the engine is shifted to the passenger side. I've tried to lift my spare Beta II block, and that thing weighs a ton!

The driver side corner is going to inherently have a little less weight on it than the passenger side. I have not measured the weight difference yet, so I cannot say for sure how drastic the difference is.
4: allows the use of OEM bolts and bolt holes for primary supports (Big PLUS!)

Now we need to design the design...

I highly reccomend hand fitting the battery into its proposed final location first. This will give you a good idea of what you want your box to look like.

take all relevant measurements that you will need to design the box.

now, its time to design the box. make lines where you'll want bends, make lines where you want to cut. And you should be able to have a design without cutting the paper much at all. I used an 11x 17 sheet of paper to make mine from.

NOTE: Even though the battery slides right into the paper model, give yourself an additional 1/8" of clearance around the battery. you sure will be pissed if you make a metal box and cant get your battery into it.
-I made mine to exact dimensions and while it fit, it was more of a tight squeeze than I would have liked, so I am reccomending that you make provisions for additional clearance

http://www.elantraxd.com/forums/attachment.php?attachmentid=1912


Alright, fold it up like you planned it, and the battery should slide right in.

http://www.elantraxd.com/forums/attachment.php?attachmentid=1913

Alright, Im happy with mine.

Now, take a metal of your choice in the shape and size you need to complete your box and accurately represent the necessary lines from your paper mock up onto the metal piece.

as I recall, my piece of metal was 10 and 1/8" wide, and 17" long.

I used 0.0625" thick galvanized steel for mine....why? because my dad's company (where all of this is taking place) keeps more of this in stock than you can imagine. The piece I took was going to be put in the scrap container.

I eventually plan on making another one of these. When I do, I plan on making it out of .125" aluminum and having it (professionally) tig welded where it needs to be welded.

This is what I would reccomend to anyone doing this modification.

I buy alot of my stuff from www.mcmaster.com
and I know they'll have the metal you want to use...no matter what it is, lol.

anyway, here's what my piece of metal looks like.

http://www.elantraxd.com/forums/attachment.php?attachmentid=1917


I used a sheetmetal shear to cut mine to size, so the cuts are straight, and the corners are also square.

god forbid you try to use a hacksaw to make this thing. I'd try to find a metalworking shop that can do some of this for you...any man willing to attempt this without at least some form of power saw is braver than I am.

I know most of you guys know this, but for some of you less experienced guys, dont try to use a circular saw to cut metal. you might be able to use it on aluminum if you know what you're doing, but its not the best idea...not to mention that the kerf is huge on those saws.

Enough babble, once you've transferred the lines, and checked your work, take it to the band saw.

here is my lined sheet metal piece being cut

http://www.elantraxd.com/forums/attachment.php?attachmentid=1918

[tharptroy]

well lets see here... now that its all cut up, it ought to look something like this:

http://www.elantraxd.com/forums/attachment.php?attachmentid=2014


Im filing the edges so that I dont slice my flesh open by accident...even the wretched OSHA might approve of this box.


now for the fun...Im taking mine to a machine called a press break (brake?). either way, here's what it looks like while its being done:

http://www.elantraxd.com/forums/attachment.php?attachmentid=2015


There, now bend all of your bends, and see it start to take shape.

http://www.elantraxd.com/forums/attachment.php?attachmentid=2016


I took this little monster to a solid steel table to do the final bends that the machine cant do. be careful where you start pounding on this thing, you wouldnt want to break anything.


http://www.elantraxd.com/forums/attachment.php?attachmentid=2017


and yes, the rest of the bends were done with a regular old hammer.


http://www.elantraxd.com/forums/attachment.php?attachmentid=2018


now...every DIY needs a little humor in it, this is where mine comes in...It becomes VERY apparent that I dont weld much, and I have very little skill when it comes to laying a bead. dont worry though, it'll hold.

http://www.elantraxd.com/forums/attachment.php?attachmentid=2019

now, line it up in the vehicle and put some bolt holes through it.

http://www.elantraxd.com/forums/attachment.php?attachmentid=2020


now, part of the positive wire needed to be extended on mine, so be sure you have the extra wire handy.

the rest is just doing the wiring, which Im sure you guys are capable of handling. I bought some expensive terminals in hopes that they'd fit better on the terminals...they dont. I was very irritated by that point, so I drilled through the tops of them to put a bolt down into the posts.

just make sure your battery posts and all connecting devices will work together before getting started.

http://www.elantraxd.com/forums/attachment.php?attachmentid=1878

[02xdGLS]

wow. very nice write-up.
big props!! :nosthumbs

[fgummett]

Nicely done, and I like the idea of relocating the lightweight battery here; in fact I hope you don't mind me borrowing it. It looks like a fairly safe place with the front cross member(?) giving it protection from below.

For those of us not as mechanically gifted or with access to as many tools there is also a ready made hold down for this battery : Hold Down Bracket [PC680]... (http://www.odysseybatteries.com/accessories/pc680hd.htm)

BTW did you get around to building the air box 'cos I plan to try the same and would welcome any tips or "gotchas" that you came across :bowdown:

[pjc6281]

Great Job!!!!!!!!!!!!!