Okay, so I'm an idiot.

Suzuki van tech question and answers.
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Brayden
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I recently pulled the battery out of the van to have it tested, and in the process I found that the battery box was stuffed - completely rusted out.

So I thought to myself, if I have to make a replacement, why should I use metal? That will just rust out again! So I dig out an old plastic bin and chop up the bottom to make a new battery box. After hours of stuffing around to make it fit, and lining it with metal straps to take the weight of the battery, I install the new unrustable battery box only to discover why it was made of metal in the first place...

The exhaust runs about 1" to the side of it. :roll: Back to square one!
F8B EFI turbo - Three pots and a snail.
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Hewball
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aluminum comes to mind there Brayden
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Brayden
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Yeah I have a sheet of the stuff that I was planning to use until the "easier" option of a plastic bucket came to mind! :snigger:
F8B EFI turbo - Three pots and a snail.
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Hewball
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if first attempt fails all you can do is try again
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eDave
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Aluminium welding is pretty tricky though isnt it?
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Jermaine
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well if u could bend it properly u could use pop rivits! just a thought!
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Josh
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Yeah, I'm down with Honda's idea...
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Brayden
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eDave wrote:Aluminium welding is pretty tricky though isnt it?
I don't have an alloy welder, so I was just going to fold and bolt. ;)
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Josh
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Sounds good to me! :wink:
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Colin
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remrmber to use the right bolts dome heads to the battery= no holes :lol:
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Brayden
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New battery box made from aluminium. It works a treat. :D

Sadly the electrical gremlin is no closer to being found. I have power to the ignition and all electrics, but the alternator won't return current to the battery. :(
The alternator is working, however there is a break in the circuit somewhere between the alternator and the battery. I can't find a fuse box for that anywhere. I HATE electrical problems - especially when I have no wiring diagram. :evil:
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Josh
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:cry:
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Colin
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simple if its a internal reg run a direct wire to the battery
if not have the regulator checked / replaced
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Brayden
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Alternator/regulator is fine, it produces current when it is spinning, but there is a physical break in the line somewhere between the alternator and battery.
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Brayden
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Well my suspicions were proven correct. The swinging alternator must have arc'd out somewhere, because some of the connectors on the return lead have been burned out, breaking the link from the alt to the battery. :roll:

So now comes the task of repairing the problem and putting the dashboard and the interior back in! Fun fun fun! :x
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