Quick-disconnect rear mount battery

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(Format images; minor clean up.)
(Undo revision 3487147 by 140.248.77.101 (talk))
 
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==Things you'll need==
 
==Things you'll need==
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*[[Battery tray with hold down]]
 
*[[Battery tray with hold down]]
 
*Disconnect switch
 
*Disconnect switch
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When you have your design roughed out on the cardboard, cut and slice the card board, bend it to the shape of the finished product. Use tape to hold it in place and tweak as required until you are satisfied.
 
When you have your design roughed out on the cardboard, cut and slice the card board, bend it to the shape of the finished product. Use tape to hold it in place and tweak as required until you are satisfied.
  
Get a piece of 24" X 24" by 1/8" steel or 5/16" aluminum plate. Place the template you made above on the plate and using a center punch, punch each inside and outside corner and draw your connecting lines. Mark the holes for the switch, solenoid, and battery hold downs and drill those first. Those punch marks and lines will be used for you to line up the brake that will bend them. If you don't have a brake, you can always have the local sheet metal shop bend them for you. Weld in extra gusset plates for strength, then weld and grind the corners. Mount the assembly to the floor of the trunk in a level area. Install battery.  
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Get a piece of 24" X 24" by 1/8" steel or 5/16" aluminum plate. Place the template you made above on the plate and using a center punch, punch each inside and outside corner and draw your connecting lines. Mark the holes for the switch, solenoid, and battery hold downs and drill those first. Those punch marks and lines will be used for you to line up the brake that will bend them. If you don't have a brake, you can always have the local sheet metal shop bend them for you. Weld in extra gusset plates for strength, then weld and grind the corners. Mount the assembly to the floor of the trunk in a level area. Install battery.
 
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==Mounting==
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Mount the disconnect switch and the Ford solenoid as shown. Wire in the solenoid to your starter using 1 gauge wire. Use 8 gauge wire to distribute power to the engine bay, dash area, and the trunk. Small 4, 6 and 8 fuse panels can be used to distribute power to where you need it.
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Take an old gun cleaning rod and dip the handle in red Plasticoat to identify the quick disconnect handle and let dry.
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{|
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|[[File:Gun rod handle.2.jpg|thumb|350px|Undipped]]
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|[[File:Gun rod handle dipped.2.jpg|thumb|300px|Handle dipped in Plasticoat]]
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|}
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*Screw in the 8-32 stud into the gun rod and crimp it in the vice to hold it in or drill the rod and put a split pin in to hold it.
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*Drill a hole in the switch handle and countersink it slightly.
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*Place a ferrule on the stud, thread through handle, place another ferrule on, and lock down acorn nut with Loctite on end of rod.
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*Adjust rod to length required.
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[[File:Gun rod handle hardware2.jpg|thumb|500px|left|Gun cleaning handle tip and hardware in order of assembly‎]]
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[[Image:Handle.jpg|thumb|left|400px|Switch knob drilled for stud]]
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[[Image:Handle_linkage.jpg‎|thumb|left|400px|Assembly mocked up]]
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[[Image:Disconect_closeup.jpg|thumb|left|400px|Closeup to show details]]
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<br style="clear:both"/>
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If you look at the pictures, you'll get the idea of how it goes together. You can drill a hole through the rear bumper or use one of the bumper bolt holes to put the rod through. Drill an appropriate hole in the trunk sheet metal, install a grommet, and your done.
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==Suppliers==
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*[http://www.plastidip.com/ Plasti Dip]
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[[Category:Electrical]]
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Latest revision as of 05:53, 7 November 2024

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