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Old 10-09-2021, 08:25 AM   #1
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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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Old 10-09-2021, 08:57 AM   #2
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Nice
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Old 10-09-2021, 12:29 PM   #3
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Great job, thanks for sharing.
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Old 10-09-2021, 12:51 PM   #4
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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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Old 10-09-2021, 12:59 PM   #5
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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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Old 10-09-2021, 07:52 PM   #6
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Quote:
Originally Posted by edge68474 View Post
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.

From the OP signature line:

" 2001 Country Coach Intrigue "Chef's Getaway" #1119"
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Old 10-09-2021, 08:01 PM   #7
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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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Old 10-10-2021, 06:16 PM   #8
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Quote:
Originally Posted by edge68474 View Post
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.
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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Old 10-10-2021, 06:22 PM   #9
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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.
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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Old 10-10-2021, 06:25 PM   #10
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Quote:
Originally Posted by edge68474 View Post
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.
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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Old 10-10-2021, 07:05 PM   #11
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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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Old 10-10-2021, 11:11 PM   #12
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Nice. Looks like you have room for additional house batteries.
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Old 10-11-2021, 03:51 PM   #13
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Nice. Looks like you have room for additional house batteries.
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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Old 10-11-2021, 06:27 PM   #14
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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.
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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