How to Build a Battery Box

Mon Feb 20, 2012 2:58 pm

Finished my battery box project for Nellie ('47 Circle Cub) this weekend. It was a fun and rewarding project.

Here's some pictures:

Started with the old battery box from my '48 Cub. It's a little ragged, but complete. This is what I used for the model; the brake is also shown:

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First thing was to make a decision about the base. I could not form/shape/mold the base of the box like the original, but needed to come up with a way to keep the overall size and look of the original. Decided to use a flat piece of sheet metal for the inside base with access holes leading to two runners. This would allow the bolt heads to be recessed and keep the looks of the box on the outside. Here's the layout of the runners:

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Next was the bottom, inside plate:

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Had to slope the ends to mimick the original:

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Now for the base:

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You can see it taking shape:

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Here, with all the sides bent:

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Next, drill out the access holes:

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Runners are ready to be welded in place:

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Cut and bent the lid and rear light holders for the back of the box, the front, and the sides. New ones are just laying on the old box on the left:

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The hardest was the top. It had to fit tight, but not too tight, encompassing the sides and front. Here's how that went:

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Layed out my lines then made a little extra cut in the corner:

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Bent the two sides, then had to use the bench vise to hold and bend the back and front (wouldn't fit in the metal brake):

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With a little adjustment and patience, the pieces are all done and welded:

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Took the seat post and differential shaft housing, bolted in the new box and new toolbox to see how they fit. Believe it's gonna work (oh yeah, had some sheet metal left over so made a couple PTO shields):

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