Builds 86 Xtra Cab Build (4Wheelunderground 3 link front, 4 link rear and 3.4 swap) (9 Viewers)

[aztoyman]

While I've been waiting for my battery box, I stayed busy. I had a couple home projects and my Ram 2500 needed some attention.

And at least related to this build, I upgraded my compressed air system since I have some painting I'll have to do on this fairly soon. I have a decent compressor but all I had into the garage was a regulator and a hose reel. Now I have water drops, auto tank drain, water separator and a Motor Guard fine filter. The hose reel is separate from the paint guns and plasma cutter air supply.

The battery box came this afternoon so I got started on that.

 

[aztoyman]

I almost changed my mind about putting it in the cab. I really couldn't find a better place though so I cut another big hole in the cab floor.

 

[aztoyman]

Test fitting.

 

[aztoyman]

Bottom view.

 

[aztoyman]

Before I welded it in, I test fit the battery and marked the locations to drill holes for the battery cables. Looks like I need to cut the tack welds on the hold down on the cover and move it to a better location.

My battery is getting old. It's been in my 52 Ford since I started grabbing parts off the 88.

I think I'm going to change the cover bolts out for knobs.

 

[aztoyman]

The flange on the box sits flat on the floor at the rear of the box. I don't like the overhang around the front and sides. The piece I cut out of the floor would cover it if I weld it from the floor to the flange. Not sure I want to though. I might be able to glue some foam and/or carpet to the sides to fill it in. I'll deal with it later.

I need to bend or grind the flange at the back of the cab for more cable clearance and clean the paint off the edge of the hole in the floor so I can weld it in. Kinda tight for cables around the cab flange in the pic.

Once the box is welded in, the cab and bed are coming off. Then I'll figure out my trans/T-case mounts. I'd rather not use the FROR style mount if I don't have to.

 

[aztoyman]

Before I weld this in, I'm thinking I better vent it somehow. AGM batteries don't vent like flooded batteries but if something went wrong I don't want the lid blowing off in the cab.

It's mounted above the frame and I don't go through water THAT deep..........on purpose anyway.

Any thoughts?

 

[aztoyman]

Something like this maybe? Amazon product ASIN B073JCZFK5
Or just drill some holes?

 

[RichardSkinner]

Looks clean! A vent is a good idea.

The kind you posted are the same type I have on my cab over camper, but it only faces rain and is in a protected location. Facing water crossings and snow melt, you may want a vent/valve type like this. They have a membrane to act as a sort of check valve.

https://www.digikey.com/en/products/detail/bud-industries/IPV-67322-B/10518884

Or a couple smaller cheaper models for insurance?

https://www.digikey.com/en/products/detail/amphenol-ltw/VENT-PS1NBK-O8002/7898277?utm_adgroup=Box%20Accessories&utm_source=google&utm_medium=cpc&utm_campaign=Shopping_Product_Boxes%2C%20Enclosures%2C%20Racks_NEW&utm_term=&utm_content=Box%20Accessories&gclid=CjwKCAjwsvujBhAXEiwA_UXnAOlSV6uzY7xGk_xWV7_2BtLCWuPuFVysQOB3x3TaAns0Nw9T41tsIBoC7WoQAvD_BwE

 

[aztoyman]

I did some research. I should NOT put ANY battery in a SEALED box. Also found out vents should be at the top since hydrogen gas is lighter than air.

Vague information as far as the size of the vent(s). Some chemist posted up some interesting info and I don't need much of an opening.

Anyway, I need to get all my mods to the box done before I weld it in.

I decided I want a drain in the bottom so I used an old bearing race and a socket for a poor man's dimple die. Drilled a hole and used a plastic plug I can pull from inside the cab if I ever have to drain it.

 

[aztoyman]

I marked the box up so I could figure out where to put my vents. They are right along side both battery vents. AGM batteries don't vent like a flooded battery but will if over charged or get too hot.

 

[aztoyman]

The lid wasn't going to work as is. The hold down was the wrong direction and blocked cable routing and not deep enough to hold the battery down. So I cut it off.

The battery terminals are only 1 " down from the lid.

 

[aztoyman]

I had some 16 gauge rectangular tubing and cut two pieces so I could leave a gap to clear the handle.

Mounted it parallel to the cables so I don't block them. I have room to glue or rivet on a piece of rubber to keep the battery secure and not let the posts touch the lid.

 

[aztoyman]

The box came with 1/4-20 screws and serrated flange nuts. I'd rather use Riv-nuts and thumb screws.

The two back Riv-nuts also go through the floor. The box is semi attached and the paint is sanded off the edges to be welded.

 

[aztoyman]

ENOUGH of this battery box. It's welded in from the top..... FINALLY. I gotta quit being so picky.

Gonna try to get the bed and cab off tomorrow. I don't have a lot of garage space left so we'll see how it goes.

 

[aztoyman]

Well I got the tires pulled, the bed off, the rear axle and links out. Then managed to get the frame lowered on the stands close to the floor so I could pull the cab OVER the engine, trans and cases.

My garage is a cluster (you know what) but I did it without breaking anything or getting hurt. Well I did bend the bracket the garage door opener hangs off.

My work space is really cramped but I'll make it work. I have plenty to do. I'll probably finish all the welding on the bottom of the cab first. That way it's ready to go for media blast. I hope that happens or I have a lot of sanding to do.

I only have one pic.

 

[88repo]

Any time you wanna bottle up some of that get it done mojo of yours and send it my way I'll gladly pay you for it.
Hell, I'll take a case, whatever the price.

 

[Manhattan]

LOVE watching the progress - even the comparatively small stuff like the batter box.

 

[aztoyman]

Change of plans. The media blast person is out of state so I'm not even going to worry about the cab.... for now anyway.

After thinking about it, I have to be able to roll the chassis out of the garage to have the room to set up a temporary spray booth for the cab.

I stuck the rear axle back in and mounted the tires. I have the suspension setting on the bump stops. I have more room to work now and it's not going to fall on me.

I got quite a bit of welding done on what I couldn't get to when the cab was on.

 

[aztoyman]

I mentioned that I don't really want to run this trans/case mount.

I think I might be able to cut and modify my TG skid plate mount so it attaches to the lower link frame brackets. I'm going to try anyway. Even though it's UNTHINKABLE to merge TG and 4WU. Sorry Brian. Uh, think of it as just a 3/8" piece of steel plate.