Well, I got the new battery box built and installed (slight delay to the start of a trip). I built the box out of 1/2 inch ply (crappy stuff these days-plywood CAN take on a compound curve on a warm day
) The box was sized for four 6 volt golf car batteries (225 ah), and there wasn't a 1/16 inch to spare in terms of height. I used the existing floor vent and the old battery box opening for gas ventilation. The floor vent was cleaned up, painted and weatherstripped. The old battery box walls were cut so that they would stick into the side of the new box as a flange--to be sealed with caulking. I installed a battery selector switch and the pos. lead runs from it to a double terminal block--this will allow hook-up of a large inverter. Future solar panels to be connected to the fuse panel, as is the new Intellicharger. I used 1g welding cable for the batteries to the terminal block, and 4g cable from the charger to the fuse panel, and from the fuse panel to the batteries--shouldn't have any line losses with those sizes!! I'll try to post photos here.