Making a Custom Battery Tray

[BenjaminCA]

If there are fabrication videos out there that make it look easy, this isn't one of them. I bring the perspective of the untrained, and inexperienced builder... If you are going to attempt to make your own battery tray, I found some issues that might come up by doing it the wrong way.

 

[Comet]

I prefer junk yard trays that can be modified but I also enjoy watching your videos.

Edit: this one did not disappoint.

 

[BenjaminCA]

I prefer junk yard trays that can be modified but I also enjoy watching your videos.

Edit: this one did not disappoint.

Modifying a junk yard tray sounds so much easier than what I just did

 

[robnicko]

Love watching your videos

Batt box looks good but I think its a bit too close to the radiator & Distributor.
Ventilation around & under the battery is important. I'd be cutting some circles (40mm) in the sides & bottom to allow air flow but not weaken the structure

 

[BenjaminCA]

Love watching your videos

Batt box looks good but I think its a bit too close to the radiator & Distributor.
Ventilation around & under the battery is important. I'd be cutting some circles (40mm) in the sides & bottom to allow air flow but not weaken the structure

Solid feedback man. I made some adjustments, and added some material for oil storage (extra quart storage) and other rags and stuff. I can get some venting going, shouldn’t be too hard. I also shortened the width, so it has more space by the distributer.

 

[Gascan]

What's wrong with the stock tray? Or are we trying to make a little oven to bake the battery?

 

[BenjaminCA]

Love watching your videos

Batt box looks good but I think its a bit too close to the radiator & Distributor.
Ventilation around & under the battery is important. I'd be cutting some circles (40mm) in the sides & bottom to allow air flow but not weaken the structure

Made a LOT of adjustments, cut some material, and added some elsewhere, but I think this is the final product.

 

[BenjaminCA]

What's wrong with the stock tray? Or are we trying to make a little oven to bake the battery?

Nothing at all. Stock tray isn’t the problem… it’s me. Had an itch I wanted to scratch and decided to make a smaller profile tray. Turns out there’s a steep learning curve. I totally get the (leave it stock, Toyota is best) crowd, but some times I like to make stuff. It was a challenge for me, but I like the end result.

 

[jonheld]

IMO the OEM fiberglass battery trays are a weak point in an otherwise robust vehicle. Tabs break easily and the OEM tiedowns tear through the fiberglass.
I bought a new one and modified it with epoxy and thin sheet steel where the tiedown hooks, and epoxied washers over the mounting ears.

 

[robnicko]

IMO the OEM fiberglass battery trays are a weak point in an otherwise robust vehicle. Tabs break easily and the OEM tiedowns tear through the fiberglass.
I bought a new one and modified it with epoxy and thin sheet steel where the tiedown hooks, and epoxied washers over the mounting ears.

thats exactly what I did as well but on my original tray, i noticed when tightening the 10mm nuts it never seemed to get tight and then saw the hook part just pulling through the side of the tray...

 

[george_tlc]

I like the toyota trays since they wont corrode etc. The hold downs are definitely a bull**** design - especially for an offroad vehicle that deals with bumps and corrugations etc.

This was my 'fix'. Some steel rod and fibreglass mat and resin. Then using some decent hooks and over the top bracket. The hooks mate with the steel rod versus ripping through the tray material. Did this for both the main & aux trays.

The toyota trays are easy to 'repair' with fiberglass mat and resin.

cheers,
george.

Major repairs down to this tray - holes patched, cracks repaired.

 

[BenjaminCA]

I like the toyota trays since they wont corrode etc. The hold downs are definitely a bull**** design - especially for an offroad vehicle that deals with bumps and corrugations etc.

This was my 'fix'. Some steel rod and fibreglass mat and resin. Then using some decent hooks and over the top bracket. The hooks mate with the steel rod versus ripping through the tray material. Did this for both the main & aux trays.

The toyota trays are easy to 'repair' with fiberglass mat and resin.

cheers,
george.

View attachment 4202443

View attachment 4202444

View attachment 4202445

Major repairs down to this tray - holes patched, cracks repaired.

View attachment 4202450

View attachment 4202446

This is the end result after some feedback from the forum and others. Made a shelf for storing some oil, atf fluid or brake fluid plus rags… the picture in the cruiser doesn’t show the air holes, or the elevated rails I welded in to keep the battery somewhat cooler. Trail and error for sure.

I’ll get it painted and throw on a rubber trim on the outer edges to protect any wiring close by.

 

[Outsane]

good stuff

 

[Gascan]

Nothing at all. Stock tray isn’t the problem… it’s me. Had an itch I wanted to scratch and decided to make a smaller profile tray. Turns out there’s a steep learning curve. I totally get the (leave it stock, Toyota is best) crowd, but some times I like to make stuff. It was a challenge for me, but I like the end result.

I think you misunderstood my point about the stock battery tray; never mind the hive mindset about “leave it stock, Toyota is best” (which I don’t always agree with either, BTW), I was pointing out that you’re making it out of a very conducive material that will hold a ton of heat (baking your battery) Vs. the stock fiberglass tray which acts as an insulator between the battery and the rest of the engine bay. As AI will say:

And the number one thing that kills all electronics, including batteries of every kind, is heat.

 

[BenjaminCA]

I think you misunderstood my point about the stock battery tray; never mind the hive mindset about “leave it stock, Toyota is best” (which I don’t always agree with either, BTW), I was pointing out that you’re making it out of a very conducive material that will hold a ton of heat (baking your battery) Vs. the stock fiberglass tray which acts as an insulator between the battery and the rest of the engine bay. As AI will say:

View attachment 4202756

And the number one thing that kills all electronics, including batteries of every kind, is heat.

Ah. Well, I added some rails to raise the battery so it won’t be sitting flush on the tray, and I’ve drilled large holes in the large back piece for ventilation. The large holes in the bottom to access the lower mounts should also help with airflow. Additionally I avoided boxing in the tray entirely to also assist with cooling. I’m guessing I could add more ventilation holes without messing with the structural integrity? I guess the days of metal battery trays have passed, I’m late to the party.

 

[BenjaminCA]

I think you misunderstood my point about the stock battery tray; never mind the hive mindset about “leave it stock, Toyota is best” (which I don’t always agree with either, BTW), I was pointing out that you’re making it out of a very conducive material that will hold a ton of heat (baking your battery) Vs. the stock fiberglass tray which acts as an insulator between the battery and the rest of the engine bay. As AI will say:

View attachment 4202756

And the number one thing that kills all electronics, including batteries of every kind, is heat.

Took your comments back to the drawing board. Definitely don’t want to cook this new battery… Added side ventilation holes (very large) as well as two slats to add to the bottom of the tray for more air flow.

 

[BenjaminCA]

The final iteration… got a primer on it. I can still drill some holes, but I think it’ll be alright.

 

[OffRoadScott]

Love the tray. The only thing that I was concerned about was access to things like the alternator, oil filter etc. As far as heat transfer yes there is some concern but you could get them painted using cerakote heat resistant stuff or use heat barrier similar to sound dampening stuff.

 

[BenjaminCA]

Love the tray. The only thing that I was concerned about was access to things like the alternator, oil filter etc. As far as heat transfer yes there is some concern but you could get them painted using cerakote heat resistant stuff or use heat barrier similar to sound dampening stuff.

Access should be decent, it’s more streamline and close fitting to the battery than a stock tray. I removed a lot of metal, should have some serious air flow around the battery rather than a closed in metal box. It’s all trial and error anyway, I’m making it up as I go lol.

 

[OffRoadScott]

Access should be decent, it’s more streamline and close fitting to the battery than a stock tray. I removed a lot of metal, should have some serious air flow around the battery rather than a closed in metal box. It’s all trial and error anyway, I’m making it up as I go lol.

Selling them, and are you doing both sides?