Battery Box Fabrication
In order properly power all of the electronics for the audio/video system, we will be using 16 SVR 2000SP batteries. There will be 8 mounted on the drivers side in a custom fabricated battery box in the old footwell location and 8 mounted in a custom fabricated battery box on the passenger side in a re-worked factory original location.
Fabricating the battery boxes.
The original footwell location needed to be cut out.
Cutting out the footwell.
The original bottom piece of the door jamb will be getting cut out and re-used in the new location of the shorter doors.
The bottom door jamb piece is welded into its' new location & the opening in the floor from the footwell was replaced with the same 3/16" steel plate that was used on the rest of the floor.
The floor extension will be installed by being clamped to 2 temporary bars.
The opening of the new battery box will be framed in with 1 1/4" solid steel bar. The weight of the batteries will be around 800 lbs. so we needed to make sure it was strong enough to support that much weight.
The bottom of the battery box will be made from the same 1 1/4" solid steel bar as the frame & will have a 1/8" steel plate skin.
Fabricating the battery box bottom.
Installing the battery box bottom.
The back wall of the battery box will be cut to fit the contour of the floor crossmembers.
Cutting out a cardboard template of the back wall.
The cardboard template was then used to trace the shape onto a piece of 1/8" steel sheet.
Installing the back wall of the battery box.
The sides of the battery box will be made from the same 1/8" steel sheet as the rest of the box.
Installing the back side panel.
The front side panel will be fabricated the same way as the other side.
The driver side battery box is complete.
The finishing touch, we capped off the edges around the opening with 1"x1" x 1/8" steel angle and added a mounting ring made from 1" x 1/4" steel flat that a plexi glass window will bolt to.
The passenger side will be done the same way as the driver side.
Original battery box door.
Cutting out the original battery box.
Re-building the lower door jamb and floor section.
Capping off the edges & adding the mounting ring.
Installing the battery box bottom.
Installing the battery box back side.
Installing the battery box rear panel.
Installing the battery box front side.
Passenger side battery box complete.
Battery Box Door Fabrication.
The battery box doors will be made from a 1/2" steel tube frame to allow for enough clearance for the plexi-glass window that will be getting installed. The door skins will be fabricated from 1/8" steel plate.
Fabricating the Battery Box Doors.
Driver Side.
Door skin cleaned & prepped, ready for hinges.
Installing the hinges.
The outside edges of the door will be trimmed out with 1/8" x 1 1/4" steel angle, this will be the sealing surface for the weather stripping.
Installing the door edge trim.
Page 1...Overview
Page 2...Floor Rebuild & Interior
Page 3...Roof Raising & Rebuild & Wall Rebuild
Page 4...Bumper Rebuild
Page 5...Rear Fenderwell Rebuild
Page 6...Door Rebuild
Page 7...Exhaust & Fuel Tank Rebuild
Page 8...Engine & Air Conditioning System Rebuild
Page 9...Stereo System Equipment
Page 10...Stereo System Install: Ring/Plug Fabrication
Page 11...Stereo System Install: Subwoofer Enclosures
Page 12...Stereo System Install: Fiberglass SST4.0 Window Speaker Enclosure
Page 13...Stereo System Install: Fiberglass Dashboard
Page 14...Stereo System Install: Fiberglass 2nd Row Center Console
Page 15...Stereo System Install: Fiberglass Front Door Panels/SST6.9 Speaker Enclosures
Page 16...Stereo System Install: Fiberglass Front Row Center Console
Page 17...Stereo System Install: Capacitor & Distrubution Racks
Page 18...Stereo System Install: Amp Racks
Page 19...Stereo System Install: Alternator Installation
Page 20...You Are Here
Page 21...Stereo System Install: Rear Door Panels/SST5.2 Speaker Enclosures
Page 22...Stereo System Install: Coming Soon
Page 23...Stereo System Install: Coming Soon
Page 24...Stereo System Install: Coming Soon
Page 25...Front Seat Bracket Fabrication
Page 26...Truck Parts
Page 27...Other Installations
Page 28...My Sponsors & Favorite Online Stores
Page 29...Funny Pictures
Page 30...Sponsor & Build Videos
