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Old 04-02-2017, 09:42 PM   #1
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Rusted/corroded battery tray supports

I was checking my batteries while I de-winterized my coach. I noticed that my battery support under my chassis battery has completely rusted/corroded through. I need to pull the batteries and get a better look, but I am sure that this will require some welding and modifying.

Has anyone experienced this? My coach is a 2000 Allure with 3 8d batteries in a non-sliding tray. Ill try to get pics tomorrow.
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Old 04-03-2017, 05:18 AM   #2
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Make sure you disconnect the inverter before doing any welding. High electrical current can destroy the inverter.
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Old 04-03-2017, 09:28 AM   #3
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John,
This is the only area on my coach where I do have some rust. Probably a combination of acid and sitting behind the rear wheel.
Mine has a plastic tray that the battery's sit in. Below that is the steel grate that is welded to the underside of the framing.
Personally I don't like how it was constructed. Once the welds break in the grating it just falls out the bottom.
I would weld a 1/2 or 3/4 metal tubing to the bottom side of the framing, then lay down some industrial grating in on top of the newly installed tubing.
I believe the two things that you have to be concerned with welding are the transmission and as stated the inverter.
Brett
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Old 04-03-2017, 11:09 AM   #4
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Before disconnecting anything. Make a drawing of the battery placement and the wiring, better yet take lots of photos. Put wire markings on the wires also.

Good Luck!
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Old 04-03-2017, 05:54 PM   #5
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Great ideas! I wouldn't have thought about the transmission and the inverter. I was wondering if a guy could make a new tray that I could drop in? Still thinking of ideas.

Brett, how was your trip to Brazels?
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Old 04-03-2017, 06:06 PM   #6
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John,
Spent the last two weeks at Zion NP. Heading to Brazels next week.
I'll keep you posted.
Brett
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Old 04-05-2017, 12:17 AM   #7
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plastic battery tray

Quote:
Originally Posted by bneukam View Post
John,
This is the only area on my coach where I do have some rust. Probably a combination of acid and sitting behind the rear wheel.
Mine has a plastic tray that the battery's sit in. Below that is the steel grate that is welded to the underside of the framing.
Brett
All,
Greetings from the UK
Do not want to highjack John's thread
Brett's mention of the plastic battery trays reminded me
Am looking to add a 3rd leisure battery to our Allure
Cannot seem to locate these plastic battery trays (to fit an 8D) on 'this side of the pond' - have tried several 'truck' outlets
Anybody in "RV land" got any ideas please
(Have parts on a container shipping out of Florida next week so could add this / these to it if I can locate stateside this week)
Thanks in anticipation - please pm me to keep the thread on track
Ian
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Old 04-05-2017, 05:22 AM   #8
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In addition to disconnecting the batteries, transmission computer and inverter, don't forget the engine control module (ECM) and HWH leveling computer. All of these devices could be subject to damage when welding on the coach chassis.
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Old 04-05-2017, 05:43 AM   #9
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I can figure out the battery and inverter disconnect, but how and where do you disconnect the ECM and transmission electronics? Is there any stored electrical charge in the inverter which could shock me when disconnecting?
In lieu of arc welding, would using acetylene gas pose any problems? (Other than preventing ensuing fire risk)
Any other way to do this? Thinking about bolt in solutions.
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Old 04-05-2017, 11:04 AM   #10
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Maybe these could be cut to suit your needs....

https://www.amazon.com/NOCO-HM485-Co...-Batteries/dp/
8D Commercial Battery Box: BatteryMart.com





Quote:
Originally Posted by IanSmith-UK View Post
All,
Greetings from the UK
Do not want to highjack John's thread
Brett's mention of the plastic battery trays reminded me
Am looking to add a 3rd leisure battery to our Allure
Cannot seem to locate these plastic battery trays (to fit an 8D) on 'this side of the pond' - have tried several 'truck' outlets
Anybody in "RV land" got any ideas please
(Have parts on a container shipping out of Florida next week so could add this / these to it if I can locate stateside this week)
Thanks in anticipation - please pm me to keep the thread on track
Ian
Exeter UK
Country Coach 2005 Allure 430 Hood River #31321
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Old 04-05-2017, 11:55 AM   #11
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Sorry, just looked at your stats, and in your '96 an ECM should not be a factor...you don't have one unless you have an after market engine. Transmission computer is under the driver area in the forward left hand compartment in most Intrigue's.
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Old 06-22-2017, 06:57 PM   #12
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UPDATE

Just an update regarding my battery compartment. I took it to a friends who is a fellow CC owner and has a lot of metal working talent. He came up with the idea to make a whole new battery tray that would drop in so we didn't have to weld on the coach. It turned out great, I can only take credit for the paint job

If you have a CC with three 8d batteries and if your supports are rusting or falling apart due to battery acid, then this is a fix for you.
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Old 06-22-2017, 07:06 PM   #13
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New tray looks great. Putting POR15 on it would go along way to keeping it new looking. Acid resistant and tough stuff.
Tray in our coach had some rust and corrosion but still structurally sound. Cleaned it up and 2 coats of POR15 along with 2 Coats of their TopCoat. I expect it should out last the coach now.
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Old 06-23-2017, 09:19 AM   #14
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Clean looking job, and yes to adding a POR15 like product.

We refreshed our 3 X's 8D compartment when we chased the two house 8D's to X's 4 L16's.

Our metal was looking in pretty good shape, with very light corrosion in some areas. We neutralized any acid, then cleaned down to bare metal in the effected areas. Washed all surfaces one more time with a paint prep cleaner. Then three products (Primer, paint (2 applications), top coat (2 applications)), that we got from West Marine. (The gent helping me is a boater, and had learned years before to even treat newer boats with some extra coatings in this high duty area! So I followed his advice, adding adult beverages and a elbow grease to the effort!).

This is now about 5 years ago, and with the chassis 8D CAT Maintenance Free battery, and the X's 4 L16 Lifeline AGM's - we have had zero problem with battery gassing/acid attack since then. I do blew the area out with compressed air to get rid of dust build up tossed up from the roadways. And as mentioned, the rear tires will throw some moisture up into the cabinet bottom from time to time. So do yearly brush and soap cleaning of the areas I can reach from above, and all along the bottom. Then rinse carefully and fully with water afterwards. Zero signs of degradation.

In I hope another 3-5 or plus years form now, when the Lifeline's need replacement. I'll go to Lithium, and an AGM starter battery. At that time, I'll close of completely the egg grate bottom, add insulation all around. Add a few up high breathing ports, with probably a pancake fan or two. The insulation, along with I think a small heating pad, will be to help keep the Lithium storage bay within good heat temperature ranges.

I like CC's, do believe they are some of the finest designed and build coaches of any era. But, like with most products, I look at some of the things CC engineers came up with - and shake my head!
-Air Cleaner intake right on the bottom of the chassis, behind where the rear passenger drives/tags toss up dirt while traveling off road.
-Needed to unattached some of the mudguard's gear to access this Air Cleaner. (Have removed our mudguard, so no longer an issue.)
-The mentioned open battery compartment bottom, behind the same wheels that toss up dust, and water when raining.
-And a few more... but those were the ones that early on with the coach, I wondered 'What were they thinking!'

Don't get me wrong, respect the chassis, coach, build, etc. - so not really complaining too much!

Best to all. And OP, thanks again for sharing your Battery Compartment Makeover!!
Smitty
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