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Old 07-22-2018, 03:31 PM   #1
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1972 31' Sovereign
Silverton , Oregon
Join Date: Aug 2014
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New Battery Box - Twice as good as the last one.

I installed my new battery box parts this morning, I got the idea from someone else here on the forum.

Our 1972 Sovereign is a center bath, and has the battery box under the range in the kitchen. Originally it was sized for 1 group 24. I had stuffed a group 27 battery in there for a while, and it sort of fit. But I had seen a reference to taking out the part of the inside of the door and running 2 batteries in the box. to do this the box has to be expanded to reach all the way into the frame rail. I took some measurements, drew up some parts. and Voila, new battery box.



I modified the door to remove the original space filler/ support piece of plastic, and adding strips of aluminum to fill the gaps, and reinforce the skin, then buck riveted it all together.

To fit the batteries, I need to add a spacer to lift the batteries up about 3/4" and get some trays to catch any errant acid. I'm still debating on cheap plastic trays and strap hold downs, or making a stainless steel tray to fit in there.



The nice part of it is, it doesn't really take much more room than the original, I may have to mount the water pump directly to it instead of the plywood shelf it had before, but that will be fine. the aluminum box lid is plenty strong enough. I think I'll add two bulkhead connectors in the back center for the wires to come through to seal the batteries from the inside space a bit better than the factory version.

I also grabbed a scrap of UHMW to line the inside of the lid to keep sparks from happening accidentally. I'm leaning towards clamping the battery cables on, and using an Anderson connector for each, kind of like the factory battery disconnect. That way I can unplug them, pull out the batteries, then deal with the cable clamps outside of the battery box.

Here's some pictures, if anyone else is interested, I can supply dxf files and dwgs for your local fab shop to make you your own, just let me know.



Picture 1 - parts made
Picture 2 - Parts riveted together with old door Modified
Picture 3 - Installed. inside lid still loose,
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Old 07-22-2018, 05:56 PM   #2
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1967 17' Caravel
Cadillac , Michigan
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You do nice work!
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Old 07-22-2018, 09:07 PM   #3
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1972 31' Sovereign
Silverton , Oregon
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Thanks, I try, I'm awfully slow though.
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Old 07-22-2018, 10:16 PM   #4
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2009 25' FB Flying Cloud
1973 31' Sovereign
Mt Angel , Oregon
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Looks good and good work!
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Old 07-24-2018, 09:49 AM   #5
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BALLWIN , Missouri
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New battery box

That is a slick idea and a professional job. Congratulations!
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Old 07-26-2018, 07:26 AM   #6
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1973 29' Ambassador
Woodward , Oklahoma
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Quality workmanship there, sir! I have been wondering how in the world to get more battery capacity on my '73 as I really need to come up with a solar system. I have always been of the opinion that if you park where you can plug in to electricity and water etc, you have missed most of the 'camping' experience. I have to run an O2 machine and sleep machine at night, and lots of state parks will not allow my Yamaha generator to run at night. I hope I'll be able to figure out a way to be completely off grid capable before next years camping season. I would genuinely appreciate a copy of your plans, etc. Thanks!
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Old 07-28-2018, 07:20 AM   #7
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1972 31' Sovereign
Silverton , Oregon
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I'll update the files on Monday and post it here sometime next week, you probably have a laser and form place somewhere near you, that would make them without shipping costs.
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Old 07-30-2018, 09:53 PM   #8
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1972 31' Sovereign
Silverton , Oregon
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Battery box Drawings

Here are pictures of the drawings.
The forum won't let me upload a .dxf flatpattern file, so send me a personal message, and I'll email them to you. then you can take them to your local laser shop.



the bend deductions are for a 1mm top die 30mm bottom die, but they should be close enough for this
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