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Okay, so I'm an idiot.
Posted: Mon Feb 27, 2006 10:27 pm
by Brayden
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.
Back to square one!
Posted: Mon Feb 27, 2006 10:32 pm
by Hewball
aluminum comes to mind there Brayden
Posted: Mon Feb 27, 2006 11:31 pm
by Brayden
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!
Posted: Tue Feb 28, 2006 1:06 am
by Hewball
if first attempt fails all you can do is try again
Posted: Tue Feb 28, 2006 6:32 am
by eDave
Aluminium welding is pretty tricky though isnt it?
Posted: Tue Feb 28, 2006 7:07 am
by Jermaine
well if u could bend it properly u could use pop rivits! just a thought!
Posted: Tue Feb 28, 2006 7:56 am
by Josh
Yeah, I'm down with Honda's idea...
Posted: Tue Feb 28, 2006 8:09 am
by Brayden
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.
Posted: Tue Feb 28, 2006 12:36 pm
by Josh
Sounds good to me!
Posted: Tue Feb 28, 2006 8:28 pm
by Colin
remrmber to use the right bolts dome heads to the battery= no holes
Posted: Thu Mar 02, 2006 9:46 pm
by Brayden
New battery box made from aluminium. It works a treat.
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.
Posted: Fri Mar 03, 2006 12:15 am
by Josh
Posted: Fri Mar 03, 2006 7:28 am
by Colin
simple if its a internal reg run a direct wire to the battery
if not have the regulator checked / replaced
Posted: Fri Mar 03, 2006 7:32 am
by Brayden
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.
Posted: Fri Mar 03, 2006 7:58 pm
by Brayden
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.
So now comes the task of repairing the problem and putting the dashboard and the interior back in! Fun fun fun!
