Step one. Bought the van.
Hello Everybody, First post. I camp a lot in tents but after spending three days straight in a tent in the rain at Dolly Sods I swore I'd make a change. Here it is. Bought it Wednesday. Dro...
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House battery frame and venting.
Not yet finished this next project but am far enough along to where I'm going to start posting about it. Hit a real slow patch which I'll go into in more detail when the postings get to it.
For the house batteries using four Energizer GC2 6 volt golf cart batteries bought at Sam's Club for around $71 each. These are the lead-acid flooded cell type. Need to create a way to secure the house batteries inside the van along with a way to vent the hydrogen gas lead-acid batteries emit while charging. Had previously built a wooden box for the batteries along with a Plexiglass vent lid back in February of 2010. Here's a link to the older project.
Considering that I've taken up welding since then, thought about revisiting this design and making the battery holder from metal. In the original battery box the four cells where in a single row with long sides adjacent.
After some reflection decide to reconfigure the battery layout into two rows instead of one. Like this.
Welded the framework from a combination of 3/4" and 1" angle iron.
The batteries will be lowered into the frame. It's not a tight fit in case the batteries expand with age. The frame will bolted to the van floor so there is no bottom. To help hold the batteries in place welded a couple of inverted bolts to the top of the frame.
A better design would have been to drill holes into the angle iron and weld nuts underneath. Didn't feel the 3/4" angle iron I was using was wide enough to allow a hole for the bolt without weakening it. If I'd used 1" instead it would have worked. Too late to increase the size without cutting on the already finished frame. Live and learn.
Welded a washer onto each outer short edge near the bottom. This will be used for the vent lid bungee cords.
Prime and paint.
Next up is to find the exact location where I'll be installing it on the floor. It's position relative to the sofa-bed is crucial. The gas tank filler hose hump placement also came into play.
I have a layer of rigid foam beneath the wooden floor for insulation. I didn't want the batteries on top of this layer so I decided to cut a hole in the wooden floor and foam layer for the batteries and the frame. This way they will sit directly on the rubber mat layer.
Also removed a bit of flooring between the battery frame and the van wall.
Good fit.
As usual I was under direct supervision while working.
continued:
Not yet finished this next project but am far enough along to where I'm going to start posting about it. Hit a real slow patch which I'll go into in more detail when the postings get to it.
For the house batteries using four Energizer GC2 6 volt golf cart batteries bought at Sam's Club for around $71 each. These are the lead-acid flooded cell type. Need to create a way to secure the house batteries inside the van along with a way to vent the hydrogen gas lead-acid batteries emit while charging. Had previously built a wooden box for the batteries along with a Plexiglass vent lid back in February of 2010. Here's a link to the older project.
Considering that I've taken up welding since then, thought about revisiting this design and making the battery holder from metal. In the original battery box the four cells where in a single row with long sides adjacent.
After some reflection decide to reconfigure the battery layout into two rows instead of one. Like this.
Welded the framework from a combination of 3/4" and 1" angle iron.
The batteries will be lowered into the frame. It's not a tight fit in case the batteries expand with age. The frame will bolted to the van floor so there is no bottom. To help hold the batteries in place welded a couple of inverted bolts to the top of the frame.
A better design would have been to drill holes into the angle iron and weld nuts underneath. Didn't feel the 3/4" angle iron I was using was wide enough to allow a hole for the bolt without weakening it. If I'd used 1" instead it would have worked. Too late to increase the size without cutting on the already finished frame. Live and learn.
Welded a washer onto each outer short edge near the bottom. This will be used for the vent lid bungee cords.
Prime and paint.
Next up is to find the exact location where I'll be installing it on the floor. It's position relative to the sofa-bed is crucial. The gas tank filler hose hump placement also came into play.
I have a layer of rigid foam beneath the wooden floor for insulation. I didn't want the batteries on top of this layer so I decided to cut a hole in the wooden floor and foam layer for the batteries and the frame. This way they will sit directly on the rubber mat layer.
Also removed a bit of flooring between the battery frame and the van wall.
Good fit.
As usual I was under direct supervision while working.
continued:
