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Old 05-12-2015, 12:53 PM   #1
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Bungled Battery Box

I have probably struggled with the battery box on my Escape more than any other item. The most pressing matter is the bolts that fasten the lid are too long. I have cut off the bolt ends but the wing nut is still too high and it's causing damage to the underside of the lid.

If you have ever lost the bolt in that tight space shown in the photograph, it is nigh impossible to get it back in position.

I can see replacing the wooden board with a piece of metal will alleviate one issue with the wing nuts. This still is a cumbersome system, I envision the metal fasteners at the bottom of the battery box bending and pulling out as you tighten the wooden (or metal) closure. The rubber grommets are getting chewed up in the tightening process, you can see I added fender washers. Using a piece of metal will alleviate one issue, this still is a system in need of a redesign.

OK, done venting. Do I have a one of a kind or have others had this issue?

Any ideas? Or do I just live with it?
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Old 05-12-2015, 01:00 PM   #2
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Quote:
Originally Posted by fudge_brownie View Post
I have probably struggled with the battery box on my Escape more than any other item. The most pressing matter is the bolts that fasten the lid are too long. I have cut off the bolt ends but the wing nut is still too high and it's causing damage to the underside of the lid.

If you have ever lost the bolt in that tight space shown in the photograph, it is nigh impossible to get it back in position.

I can see replacing the wooden board with a piece of metal will alleviate one issue with the wing nuts. This still is a cumbersome system, I envision the metal fasteners at the bottom of the battery box bending and pulling out as you tighten the wooden (or metal) closure. The rubber grommets are getting chewed up in the tightening process, you can see I added fender washers. Using a piece of metal will alleviate one issue, this still is a system in need of a redesign.

Any ideas? Or do I just live with it?
Maybe replace the wood strip with a thinner piece of steel or aluminum?
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Old 05-12-2015, 01:32 PM   #3
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They make "clips" that attach to the long bolts that hold the battery in place.
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Old 05-12-2015, 01:56 PM   #4
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Looks like a rubber washer underneath the metal one; mine only has the metal one. Would removing the rubber washer make a difference?
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Old 05-12-2015, 02:24 PM   #5
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How about taking a piece of flat bar, say 2" long, 3/4" wide and 3/16" thick, drilling and tapping a hole to make a "flat" low profile wing nut. You could still remove it without tools.

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Old 05-12-2015, 03:34 PM   #6
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The rubber washers are down at the other end of the threaded rods on mine, keeps the bent part from falling off. Mine is a long dual 6v box.

I do get a distinct smell when the batteries are charging at a high voltage, up over 15 volts. Need to find a better way to vent them. These boxes are side vented as opposed to top vented.
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Old 05-12-2015, 03:50 PM   #7
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The lid on my battery box came from ETI fastened down with nylon straps, no bolts.
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Old 05-12-2015, 04:12 PM   #8
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Quote:
Originally Posted by fudge_brownie View Post
..... Do I have a one of a kind or have others had this issue?

Any ideas? Or do I just live with it?
How about a knurled nut or thumb screw. If you have a hardware store like mine nearby, they'd have such a thing.

Or, if you can silver solder or braize, you can make one.

Get seven hex nuts the proper thread size, position six in a hexagonal ring around the center one, and solder or braize them all together. It will give you plenty to get your paw around, and total thickness is one nut high.
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Old 05-12-2015, 07:06 PM   #9
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Originally Posted by dfandrews View Post
How about a knurled nut or thumb screw. If you have a hardware store like mine nearby, they'd have such a thing.

Or, if you can silver solder or braize, you can make one.

Get seven hex nuts the proper thread size, position six in a hexagonal ring around the center one, and solder or braize them all together. It will give you plenty to get your paw around, and total thickness is one nut high.
Drilling and tapping a hole in a short piece of flat bar is just so much quicker

Ron
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Old 05-12-2015, 07:42 PM   #10
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Originally Posted by Ron in BC View Post
Drilling and tapping a hole in a short piece of flat bar is just so much quicker

Ron
True that. (I confess: I saw "flat bar" and assumed,
instead of reading the rest of your post,
so I missed your actual solution.)
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