Larger battery box

[rp709]

Has anyone replaced the standard tongue mounted battery box with a larger one suitable for golf card batteries (why doesn't Airstream make a slightly larger box?)

[field & stream]

As others have reported doing, we had a dealer modify the battery box height to accommodate golf cart batteries by removing the lid, adding C-channel, replacing the lid and repainting with factory paint. Looks original. Good question why Airstream does not offer this setup as an option, especially as part of a solar package.

[Ktholin]

I recently had my battery box modified by the guy who installed my solar system. He cut the bottom off and spot welded in a lower bottom. The advantage of doing it this way is it doesn't add to the height of the box which will interfere with my front storage lid (I have a 25 foot FB with twin beds.

The battery box still looks original and the cost was about $200.




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[dkottum]

Originally Posted by rp709

Has anyone replaced the standard tongue mounted battery box with a larger one suitable for golf card batteries (why doesn't Airstream make a slightly larger box?)

Maybe because our Airstream Owners Manuals state that 10% of the trailer weight should be on the tongue, but never more than 1,000 pounds.

[rp709]

I think Airstream is worried about added weight on the tongue and keeping the battery box smaller is their way of regulating that. I'm wondering if the original box can be removed and how expensive fabricating a new larger one would be. I do like the idea of lowering the bottom.

[Ktholin]

Lowering the bottom is an elegant solution. I'm very happy with it, and the look is entirely original. I estimate that changing out to two 6v golf cart batteries probably added 30 pounds. Just not enough to fret about.


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[rp709]

I have been using 2 Trojan 105 golf cart batteries for several years. This was a good addition. I added some hardwood spacers to raise the lid. I don't care for the look. Do you have pictures of the box modification?

[Ktholin]

I'll post what I can tomorrow.


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[Ktholin]

Attached photos show 6V golf cart batteries in original battery box, maintaining top profile. Lowering the bottom can probably be done in a number of ways. In this case, two L brackets were welded to bottom with plate between.








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[Gringo]

Nice. Thanks for that idea. I just went to all GC batteries in our sailboat and will be buying two for the AS in the next few weeks.

[fotoman1527]

I'm going through this identical problem of trying to upgrade house batteries to golf cart batteries with a newly-acquired 2012 flying cloud 27. The Trojan T-105 RE batteries that the manufacturer says would be perfect for boondocking are a bit less than 2 inches too tall. A local welder says he can't do anything with a welded battery box, although I am going to email him pictures of the L-bracket solution in this thread.

I wonder if anyone has done an end run around this problem by locating robust golf cart batteries with a lower profile that fit in the existing box, without modification, or whether everyone who chose to upgrade their batteries to golf cart batteries has found someone to recraft their battery boxes.

Thanks!

[idroba]

See post #18 on this thread for how I gained the height necessary for the Golf Cart type batteries.

http://www.airforums.com/forums/f449...-124829-2.html

[fotoman1527]

Thank you for your response!

I see that you added height to the top of your battery box:

"I mitered the corners and put small L brackets inside the channel for stiffness, then attached it to the top of the battery box with sheet metal screws (or pop rivets) then attached the original top of the box to the new frame."

If I add height on my flying cloud 27 battery box - AT ALL! - it will block access to the storage locker that sits next to the battery compartment. I hope you can see that in the enclosed picture.

I'm wondering if I put two of the largest batteries that can fit in the box as is that will dramatically increase my boondocking capabilities to a similar extent as using the Trojans. For example, a local battery store is recommending a pair of Group 31 Deep Cycle batteries, arguing they will give me "a considerable upgrade." They fit. I have to get the specs to compare. Has anyone gone that route? Do you have an opinion on the two choices? Thanks!!!!

[SCOTTinNJ]

Group 31's fit?

[No. 13]

Hi fotoman... my local Airstream dealer had a highly upgraded show unit on the lot with a 2-inch extended battery box...they cut the bottom out and added 2 inches ...rewelded it and painted it...looks perfect I had them do the same to mine.

[idroba]

Originally Posted by fotoman1527

Thank you for your response!

I see that you added height to the top of your battery box:

"I mitered the corners and put small L brackets inside the channel for stiffness, then attached it to the top of the battery box with sheet metal screws (or pop rivets) then attached the original top of the box to the new frame."

If I add height on my flying cloud 27 battery box - AT ALL! - it will block access to the storage locker that sits next to the battery compartment. I hope you can see that in the enclosed picture.

I'm wondering if I put two of the largest batteries that can fit in the box as is that will dramatically increase my boondocking capabilities to a similar extent as using the Trojans. For example, a local battery store is recommending a pair of Group 31 Deep Cycle batteries, arguing they will give me "a considerable upgrade." They fit. I have to get the specs to compare. Has anyone gone that route? Do you have an opinion on the two choices? Thanks!!!!

Yes, those Airstreams with the front door compartment cannot use the raise the box height solution. They could use the lower the bottom system as shown in the other posts. I think the lower the bottom solution is quite a good one where it is needed.

You can shoehorn two group 27's into the original battery box, with some minor metal work, but I don't think group 31's will fit. Golf cart batteries have been made in one standard size for years and years, and there are (to my knowledge) no alternative sizes with the same capacity and that are true deep cycle batteries.

[fotoman1527]

To the point - why not just add an inch or two in height to the battery box, I took that issue up with Airstream HQ tech support, and the answer I got was that an overwhelming number of AS users just use their rigs on shore power. I took that to mean that not enough folks had asked for it. She also said that there was no great weight concern about increasing the box slightly to accommodate the larger batteries, and that I was free to do that. Of course, their engineers might take a different view, but that's what a tech rep told me.

[idroba]

Originally Posted by fotoman1527

To the point - why not just add an inch or two in height to the battery box, I took that issue up with Airstream HQ tech support, and the answer I got was that an overwhelming number of AS users just use their rigs on shore power. I took that to mean that not enough folks had asked for it. She also said that there was no great weight concern about increasing the box slightly to accommodate the larger batteries, and that I was free to do that. Of course, their engineers might take a different view, but that's what a tech rep told me.

We need to let Airstream know that there are a significant number of us who do boondock and would like an option of a decent battery system, a decent converter/charger, a decent solar system and good capacity water and holding tanks. (my FC 20 has all of 23 gal fresh water capacity). What do I get instead? An over complex radio/TV/sound system I don't want, need or use and tinted windows so dark I have to have lights on with any day less than brilliant sunshine. Grumble, grumble. Give us an option at least. Call it the Boondock option.

[Mrjkq]

The new 2016's come equipped with an upgraded larger battery box. They can probably be obtained through Airstream.

[AWCHIEF]

My solution,