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Old 02-10-08, 06:14 PM   #3 (permalink)
SF80
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Join Date: Nov 2007
Location: SF CA
Posts: 228
The next step was to install the new battery tray kit from CDan.

This kit consisted of the battery tray, OEM battery tray bolts, j-hooks, hold down bar, hold-down nuts, and even battery cable hole rubber grommets. VERY complete.

Step 1 was to trim the battery tray so it would fit in the location. The front inner (right-side) has to be trimmed back about an inch and a half following the contour of the radiator. I used a jigsaw on slow speed to cut the tray, as CDan told me that there is fiberglass in the tray and had warned against grinding.

I then had to lower the high-pressure AC line to get the tray to fit height-wise. I simply removed the rubber bushing and that netted me enough height to position the tray.

I also had to use a step drill bit to "open up" the 2 lower mounting holes in the tray to get them to line up with the holes in the fender.

The new tray will dislocate another wire harness that I ended up mounting to the battery tray.

Picture 1 is the shifted AC line

Picture 2 is the trimmed battery tray
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Brian

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'95 FZJ80 | Emerald | locked | Slee 4" & BFG AT 315's | Hellroaring Dual Battery | 150 amp-ed | MAF-ed | Scion-ed
'08 BMW 135

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