Technical Louvered batterybox from scratch - techweek

I was thinking what kind of batterybox or tray to use with my shoebox build.The oem battery trays leave battery exposed and autopart stores sells mostly a plastic crap,so i decided to make my own.

Here is the start,cut some sheetmetal and marked it:



The box needed few dimples,so i made this dimple tool with lathe.I used a hydraulic press to make the dimples with these dies:



The next phase was to roll some beads with beadroller and make dimples:



Then i used metal brake and after that made testfitting to Fords inner fender:



It needed some bracing,so the battery's weight didnt twist it:



And again some testfitting with a junk battery i had.I made a temporary battery hold down bar too:

 

Where are the louvers? I can't see them anywhere.

..................... Jack

 

And now the louver part.I do not own a louver press,i've heard that some guys punch them in here Finland,but i dont have a clue who does them.I noticed that a fellow hamber marioD from Germany punches them.I know that people from Germany have a good quality in their products and their scheduling works like a clock,so i hired him to punch some louvers for me.I got a package from Germany,just what i was looking for.Thanks Mario!



Then i had to some work with the sheetmetal brake again:



I made dimples on the box lid too and welded the corners:



After that was time to mount the louvered skin on the box frame with clecos:



And the welding is done



I made holes for the cables and wires,the grommits are there too:



This is the battery hold down bar,the studs are for the lid:

 

Then some testfitting with the inner fender again:



The crappy battery is there too:



Then i took a pile of parts for the powder coater,including the box:



Here is the finished box

 

Nice work! HRP

 

Nice way to hide a nasty battery !

 

Super nice job!!

 

Very cool...

 

Good looking box .......

Lynn W

 

Nice job!!

 

Put an acorn nut on top of the exposed hold down studs....I have a 6 inch scar on my arm from one......

 

Thank you all!
Yeah,those studs are long,but i used what i have in my stash.Plan is to get shorter studs,or cut those shorter before i cut myself...
Its just not easy to find non metric studs in here from hardware stores.I always use unf's/unc's when i build my Harley or US made cars.
It could be easier to surrender and get the damn metric bolts and nuts from the local hardware store.
I guess some people call it stupidity,but i call it obsession

 

Nice and it is ventilated so there will be less corrosion.

 

Yeah,thats the idea.I drilled few drainholes too on the bottom beads

 

Excellent turnout!
Was a pleasure to punch for you

 

Thanks!
I'll contact you,if i need louvers in the future

 

VERY NICE

 

Just remembered that i had a bunch of acorn nuts,which i bought when i was building my bike.
So,just for shits & giggles,i changed the studs to shorter ones and put the acorn nuts on the top:



I think it looks better(and a bit safer too) with the acorn nuts,but its not so practical than its with the wingnuts..
Well,i guess i can live with that.Thanks for the suggestion!

 

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