Hey all, thought I'd put together a quick post on how to make your own modification to the stock battery tray which will make the Optima that many of us use more secure, and a factory-looking install.

Sorry, can't figure out how to get these photos to display rather than link.

Here's what you will need:

A 28" length of 2" wide, 1/8" thick aluminum stock
A 2" long M8 bolt with 2 washers, 2 nuts, and 2 lockwashers
A gallon (or less) of Plasti-Dip or equivalent



STEP 1: Cut stock to length, then bend in the following dimensions:

top = 10"
sides = 7"
left side lower tab = 2.5"
right side lower tab = 1.5"

Use these pictures as a rough guide:




Left side, drill a oblong hole about 1" long and 1/2" wide closer to the terminal side of the stock and starting 1/2" from where you made your bend.

http://img241.imageshack.us/my.php?image=img1681cl8.jpg


Right side drill a round hole 1/2" diameter right after the bend in the same position as the other side.

http://img258.imageshack.us/my.php?image=img1683sx9.jpg



STEP 2: Coat in Plasti-Dip. This creates a rubber coating which is useful to have when you're mounting something so close to the terminals. 3 coats was enough for me and didn't cause any problems with the resize of the dimensions. Be sure to sand the surface a bit rough first before coating so it sticks, then let dry for a few hours between coats for a uniform finish.

Coating

http://img211.imageshack.us/my.php?image=img1684zw8.jpg


Finished product

http://img161.imageshack.us/my.php?image=img1687zt1.jpg



STEP 3: Remove the stock battery tray. On the right side there's a convenient non-threaded hole. This is where you want to mount the stud with the M8 bolt. Put the bolt through the underside and secure with the nut and lockwasher. There's a gap under and over the tray - almost like they were asking for precisely this. There will still be sufficient thread to put another nut on top when you mount the bracket.

http://img255.imageshack.us/my.php?image=img1689df4.jpg

http://img255.imageshack.us/my.php?image=img1690be1.jpg



STEP 4: Disconnect the battery, put the bracket on top, and secure on each side. The stock bolt will fit in a new hole on the factory tray which is close to the new battery location.

http://img444.imageshack.us/my.php?image=img1694nm5.jpg

http://img263.imageshack.us/my.php?image=img1695qu0.jpg

http://img297.imageshack.us/my.php?image=img1696xf2.jpg



That's it. It was pretty easy, and truly looks like a factory job. There is no chance that this battery will go anywhere now, and I feel more secure throwing the car around corners now. The other options just weren't working for me.



I hope this helps more people use these great batteries that may have previously been put off by the lack of options as far as mounting is involved. Anyone has any questions, feel free to ask.

Regards

 

60 hits and no comments? Can anyone tell me how to get the pics to display properly here?

Thx

 

I think you need to be member to post pics, no?

 

I am a member - paid in full. Still doesn't show up correctly.

 

Jim,
Nice work! You need to add [IMG] before each URL and [/IMG] after.

Andreas

 

Not true. I think all you need is a minimum of 5 posts, and you can post pics.

Signed: Chief "Pic Patrol" Officer

 

Oh, now you are a "chef" also

 

Yeah, I gave myself a promotion and doubled my salary! I figured 200% of $0 sounds like a lot more $$$ than 100% of $0!

BTW - I do make killer Cream Puffs! I really do!

 

Ooohhhh You said "chief".........never mind

 

You were probably still on your first cup of coffee, so that is understandable!

 

I realize the bracket is coated, but should you be concerned about having a metal bracket so close to the exposed metal of the battery cable ends near the metal bracket?

 

Suggestion would be to notch out the bracket close to the positive terminal to give it a little more clearance.

 

Nice DIY. Looks like alot of work.

 

very nice idea. i think i will do all my bats now. i would go w/1" thick as to create more space from the battery posts.

where did you buy the aluminum stock from?

to post images you need [img] full path to image location [/img]

lets give a try

 

hmmm, didnt work.