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10-09-2021, 07:25 AM
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#1
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Senior Member
Join Date: Aug 2019
Location: A beach or race track near you.
Posts: 687
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Battery Box Rebuild
When I purchased my coach, the previous owner advised me that he had "repaired" the battery box after having the batteries fall out in the road on the way to Florida. His repair was basic at best and I knew it would need to be addressed in the future.
Last Friday the time finally arrived to address this issue. My race car chassis builder, Bret Hamilton, took the whole day and gave me a hand with this project, (He is truly a gifted fabricator and a great friend) We removed the 3/4" plywood floor the PO installed for a battery box floor, an and cut out the remaining rusted sections. These were replaced with new steel and two new floor supports were added to the center of the box to help carry the weight of the batteries. He then made a new floor using perforated stainless steel sheet to replace the factory expanded metal ( most of the factory floor was gone, it is what fell out in the highway).
Once finished at the fab shop, I brought the coach back home and treated all the new and old steel with Ospho rust converter and let it sit overnight. Then everything got a fresh coat of Rustoleum satin black. I used aluminum angle to make locators for the batteries (which will be replaced very soon with 6 volt golf cart for house) and I added more protective wrap to some of the battery cables and tried to neaten them up as best I could.
I am more than happy with how it turned out and I certain it will last another 20 years.
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2001 Country Coach Intrigue "Chef's Getaway" #11199
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10-09-2021, 07:57 AM
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#2
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Senior Member
Join Date: Nov 2012
Posts: 1,293
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Nice
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Wally & Elta Mae
2007 Allure 470 Sunset Bay #31535
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10-09-2021, 11:29 AM
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#3
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Senior Member
Join Date: Jan 2018
Location: Traveling
Posts: 553
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Great job, thanks for sharing.
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-Dave
2003 Country Coach Allure First Avenue 36; 2012 Honda CR-V
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10-09-2021, 11:51 AM
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#4
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Junior Member
Join Date: Jan 2017
Posts: 9
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Looks great, I need to check mine as well and see if this project is in my future.
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10-09-2021, 11:59 AM
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#5
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Senior Member
Join Date: Oct 2017
Posts: 1,937
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Nice work. Good to have friends, even those who can't fabricate. A plus for you.
Wondering how long the original box lasted. What is the year and model coach please?? I may have to take a good look at mine.
Thank you.
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Larry & Sheree & KD the CAT
2009 Holiday Rambler Admiral 30SFS Lewis County, Wa.
USN 1964-68, USS LEXINGTON CVS-16
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10-09-2021, 06:52 PM
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#6
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Senior Member
Country Coach Owners Club
Join Date: Feb 2019
Location: Tucson AZ
Posts: 457
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Quote:
Originally Posted by edge68474
Wondering how long the original box lasted. What is the year and model coach please?? I may have to take a good look at mine.
Thank you.
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From the OP signature line:
" 2001 Country Coach Intrigue "Chef's Getaway" #1119"
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John
2007 Country Coach Tribute; Cat C9 400; 2012 Ford Edge toad; Roadmaster Blackhawk 2 10,000 lb tow bar; Demco AF1 Braking System; 2007 BMW K1200LT Hannigan Trike Conversion; Member, IEEE, NFPA, PMI, NRC SRO (Ret).
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10-09-2021, 07:01 PM
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#7
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Senior Member
Join Date: Mar 2019
Location: Lansing MI
Posts: 2,825
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All in all a nice job. But, you may want to rethink the aluminum against the stainless steel, it will likely result in galvanic corrosion unless you insulate them from each other with some plastic or wood. Good luck.
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An Old Fisherman
2017 Nexus Ghost 36DS, 2014 Ford F150 Long Bed
2007 Harley-Davidson Ultra Classic
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10-10-2021, 05:16 PM
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#8
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Senior Member
Join Date: Aug 2019
Location: A beach or race track near you.
Posts: 687
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Quote:
Originally Posted by edge68474
Nice work. Good to have friends, even those who can't fabricate. A plus for you.
Wondering how long the original box lasted. What is the year and model coach please?? I may have to take a good look at mine.
Thank you.
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We bought the coach in the beginning of 2020 (Just before the World lost it's mind) and I believe the batteries fell out in January 2019, when PO left headed for Florida. He did not get far, and luckily was able to make it back home some how.
The original support braces were gone completely and he made a floor from 3/4" plywood (which, by the way did not sit level, and cause batteries to slide towards the door as you traveled down the road).
There was still pretty fair amount of rust in the rear most support, which we cut out and replaced completely, and the front corner, behind the tire was getting bad. We cut out approx 8" of the corner, far enough to get back to solid steel and welded in new section. Also added two new center supports to carry the weight of the batteries, and support the stainless steel.
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2001 Country Coach Intrigue "Chef's Getaway" #11199
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10-10-2021, 05:22 PM
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#9
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Senior Member
Join Date: Aug 2019
Location: A beach or race track near you.
Posts: 687
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Quote:
Originally Posted by arcaguy
All in all a nice job. But, you may want to rethink the aluminum against the stainless steel, it will likely result in galvanic corrosion unless you insulate them from each other with some plastic or wood. Good luck.
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I had looked into some very nice plastic trays that also incorporate hold downs for the batteries, but space is at a premium.
When I upgrade to the 6 volt golf cart batteries, I will try to come up with something better and again, I do need to come up with a hold down as well.
I have seen plastic banding straps used as hold downs. They do a good job, just tough to deal with if you have to every take them loose. Also though about the same straps like used for boat batteries. I'm always on the look out for just the right thing.
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2001 Country Coach Intrigue "Chef's Getaway" #11199
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10-10-2021, 05:25 PM
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#10
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Senior Member
Join Date: Aug 2019
Location: A beach or race track near you.
Posts: 687
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Quote:
Originally Posted by edge68474
Nice work. Good to have friends, even those who can't fabricate. A plus for you.
Wondering how long the original box lasted. What is the year and model coach please?? I may have to take a good look at mine.
Thank you.
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I don't know how a man makes it in this world without friends. I am lucky to have several friends that are so talented and are willing to help me when I ask.
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2001 Country Coach Intrigue "Chef's Getaway" #11199
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10-10-2021, 06:05 PM
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#11
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Senior Member
Join Date: Jul 2012
Posts: 887
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looks like you guys did a good job. This is definitely in my future too...I've been putting it off. Thanks for sharing.
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Mark
2002 40 PWD Monaco Windsor
Flat Towing Honda CR-V
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10-10-2021, 10:11 PM
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#12
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Community Moderator
Join Date: Sep 2011
Location: Between the Oceans
Posts: 8,034
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Nice. Looks like you have room for additional house batteries.
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Steven & Polly
2000 Country Coach Intrigue 40' ISC 350
2018 Ford Explorer 4WD
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10-11-2021, 02:51 PM
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#13
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Senior Member
Join Date: Aug 2019
Location: A beach or race track near you.
Posts: 687
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Quote:
Originally Posted by CountryFit
Nice. Looks like you have room for additional house batteries.
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I want to go with four 6 volt golf cart house batteries and do away with the 8D that's in there now (don't think it's even a deep cycle ???) I'm pretty sure I have room, just not much "Extra" room. The two group 31 chassis batteries are too long to fit end to end so that hurts. I'll figure out something and I look at every other CC I can to see how they are laid out. I think these coaches had Three 8D's from the factory, 1 start and 2 deep cycle. My back hurts just thinking about that LOL
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2001 Country Coach Intrigue "Chef's Getaway" #11199
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10-11-2021, 05:27 PM
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#14
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Senior Member
Country Coach Owners Club
Join Date: Jan 2006
Location: Northern California
Posts: 5,868
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Quote:
Originally Posted by arcaguy
All in all a nice job. But, you may want to rethink the aluminum against the stainless steel, it will likely result in galvanic corrosion unless you insulate them from each other with some plastic or wood. Good luck.
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FWIW, my 4 golf cart house and 2 8D starting batteries sit on separate steel trays.
A plastic tray liner sits inside of each tray between the batteries and the floor of the tray.
None are strapped to the tray.
Still working after 26 years here in our arid environment.
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Dean
1995 38' CC Magna #5280 **** Sold after 21 years of enjoyment.
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