another battery box woes post

mrloco · 08-05-2009, 09:09 PM

Well, I've lost my battery box. I purchased a new battery that was just a tad ~1/2" taller than the one that came with my hi-bird 250. It fit very snug in the box but i was able to get it in and closed.

Went for a ride and when I got home the battery was hanging to the side by the wires. No box in sight.

I'm not inclined to relocate it under the seat at this time -- seen some threads on that and I'm not sure I'm proficient enough yet. I am thinking of cutting and jb-welding a sheet metal box to replace the plastic one I lost.

Any thoughts? Is jb weld good enough/strong enough to hold together? Anyone done something like this or have a better suggestion?

Thanks for the help.

Weldangrind · 08-06-2009, 01:25 AM

Welding is always my preference. Guess why?

If you can't / don't want to weld, I would recommend mechanical fasteners over JB. If your box attaches to round tube (unfamiliar with your bike), then you could use conduit clamps and bolts with nyloc nuts. Conduit clamps are cheap, and they resemble a question mark in shape. They are usually about 3/4" wide.

Would that work?

AZ200cc · 08-06-2009, 02:30 AM

Rivets, Screws, Have a welder make something, but JB weld is nothing but a glorified super glue or epoxy.

.

frostbite · 08-06-2009, 07:49 AM

Agreed, it's great for trailside patching/temp repairs (cracked cases/covers etc...) but definitely not a long term solution.

Quote:

Originally Posted by AZ200cc

Rivets, Screws, Have a welder make something, but JB weld is nothing but a glorified super glue or epoxy.

.

mrloco · 08-06-2009, 07:54 AM

Thanks for the advice. I'll work out a mechanical fastener solution, then. Much appreciated.

Cal25 · 08-06-2009, 08:17 AM

Go with rivets. Should be able to get a cheap rivet kit for about 10 bucks.

FastDoc · 08-06-2009, 11:27 AM

I re-enforced mine with Gorilla tape. My bike is ridden almost all off pavement and it's help OK so far.

Weldangrind · 08-06-2009, 12:12 PM

Can you start with a donor battery box from the local bike wreckers?

undertulsa · 08-07-2009, 11:18 AM

my battery box was having fractures after 300mi, pulled took to my brother welded all the corners and gaps and attachement posts. Welded some metal to the back of the box to give some strength. Nice and sturdy now.

Would like to get fab'd outta stainless by a machine shop but prob cost 200.00+ dollars.

mrloco · 08-09-2009, 09:56 AM

Well thanks for all the advice. I wound up picking up a piece of 1/8"x1" steel stock from the local hw store, cutting 2 pieces then bending them around the battery with an extra 2" tongue to bolt onto the battery-box's original mount points. Holds quite snug. Right now I'm using some tape to keep the batt from sliding horizontally when there's vibration but will add a horizontal cross piece and something to attach a strap.

Works well and certainly won't break.

Fun (not really) part was i don't ahve a vice so I used a 15" crescent wrench, a hammer, and a brick wall to get the bends (no they ain't pretty).

Thanks everyone for your suggestions.

08-05-2009, 09:09 PM	#1
mrloco Join Date: Jun 2007 Posts: 15	another battery box woes post Well, I've lost my battery box. I purchased a new battery that was just a tad ~1/2" taller than the one that came with my hi-bird 250. It fit very snug in the box but i was able to get it in and closed. Went for a ride and when I got home the battery was hanging to the side by the wires. No box in sight. I'm not inclined to relocate it under the seat at this time -- seen some threads on that and I'm not sure I'm proficient enough yet. I am thinking of cutting and jb-welding a sheet metal box to replace the plastic one I lost. Any thoughts? Is jb weld good enough/strong enough to hold together? Anyone done something like this or have a better suggestion? Thanks for the help.
	0

08-06-2009, 01:25 AM	#2
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Welding is always my preference. Guess why? If you can't / don't want to weld, I would recommend mechanical fasteners over JB. If your box attaches to round tube (unfamiliar with your bike), then you could use conduit clamps and bolts with nyloc nuts. Conduit clamps are cheap, and they resemble a question mark in shape. They are usually about 3/4" wide. Would that work? __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
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08-06-2009, 02:30 AM	#3
AZ200cc Join Date: Apr 2007 Location: Show Low Arizona Posts: 2,889	Rivets, Screws, Have a welder make something, but JB weld is nothing but a glorified super glue or epoxy. . __________________ <br />2001 Suzuki DR200SE<br />1997 Suzuki RM250 YIKES<br />1995 Yamaha Breeze 125 daughters<br />1991 Honda XR80r Restored<br />maybe a 2003 Yamaha TTR90
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08-06-2009, 07:54 AM	#5
mrloco Join Date: Jun 2007 Posts: 15	thanks - will give mechanical fasteners the nod Thanks for the advice. I'll work out a mechanical fastener solution, then. Much appreciated.
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08-06-2009, 11:27 AM	#7
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	I re-enforced mine with Gorilla tape. My bike is ridden almost all off pavement and it's help OK so far. __________________ Happy to serve.
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08-06-2009, 08:17 AM	#6
Cal25 Join Date: Feb 2008 Location: Terrell and Grapevine Tx. Posts: 1,585	Go with rivets. Should be able to get a cheap rivet kit for about 10 bucks.
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08-06-2009, 12:12 PM	#8
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Can you start with a donor battery box from the local bike wreckers? __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
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08-07-2009, 11:18 AM	#9
undertulsa Join Date: May 2009 Posts: 219	Stress Fractures my battery box was having fractures after 300mi, pulled took to my brother welded all the corners and gaps and attachement posts. Welded some metal to the back of the box to give some strength. Nice and sturdy now. Would like to get fab'd outta stainless by a machine shop but prob cost 200.00+ dollars.
	0

08-09-2009, 09:56 AM	#10
mrloco Join Date: Jun 2007 Posts: 15	resolved Well thanks for all the advice. I wound up picking up a piece of 1/8"x1" steel stock from the local hw store, cutting 2 pieces then bending them around the battery with an extra 2" tongue to bolt onto the battery-box's original mount points. Holds quite snug. Right now I'm using some tape to keep the batt from sliding horizontally when there's vibration but will add a horizontal cross piece and something to attach a strap. Works well and certainly won't break. Fun (not really) part was i don't ahve a vice so I used a 15" crescent wrench, a hammer, and a brick wall to get the bends (no they ain't pretty). Thanks everyone for your suggestions.
	0