As mentioned in a post or two above, I picked up a new Optima battery box from Dan at Ruff Stuff Specialties. I figured this would be an easy job and I knock this out in no time. I was a tad wrong. The box is installed, but it turned out to be a bigger pain in the rear than I expected. Here is what I did to get that box installed.
Photo 1: I started this project by priming the box while hanging it from my favorite parts tree. I applied a couple coats of Krylon primer after washing off the oil with warm water and TSP.
Photo 2: A little while later and I had a couple coats of satin black on the batter box, on my hands, the courtyard concrete, and the parts tree. Hey, there's the Frog in the background. Hey, Frog!
Photo 3: I actually left the box to cure overnight, and we went fishing in the morning. No fish, but it was nice to get out and do some mild wheeling and throw in the line. Here is the stock battery box, sans battery. This is where the job got tricky.
Photo 4: You see, in the photo below, you can tell that there is no easy way to mount the battery box. If you take out the plastic tray, you have nothing flat to set the box on. If you leave it in, the radiator hose and cruise control unit are in the way. Some modding has to be done...
Photo 5: Here is a close up of the radiator hose contacting the box. I was not about to mount the battery box like this.
Photo 6: Removing the plastic box is easy. Just three bolts hold it on place. Here you can see the original box and the new box designed for the Optima battery.
Photo 7: I decided to take my dremel and cut away the plastic edge opposite from the radiator hose. This would enable me to scoot the Optima an inch to the left while still maintaining a strong battery box.