Battery box.

[Hutch]

Went to the caravan today to remove the battery to bring home as we cannot get away for a month or maybe two.
Removed the battery and noticed the rear right hand, lower corner of the battery box is cracked.
I realised this is where I have strapped the battery in tight and the battery tray is very sharp and square. The battery box in the lower corner is rounded, and has now cracked, so I will have to make a repair.
I intend to put a small raised wooden plank in the bottom of the box to keep the battery tray away from the corner. Yet again a bad design feature. Had the van 10 years and never noticed it before. . Photos next time at the van.

 

[audiorob]

Just googled ‘plastic trunking corner’ and found several options including some with curved corners that maybe could be trimmed to provide reinforcement for the corner? Do you have access to undertake the repair from inside the van? From your description I wonder if the moulded abs shell is vulnerable in the corners?

 

[Hutch]

I think I will repair from the inside of the battery box, raise the battery support by 1/2 inch which will give clearance for the corner of the battery tray.
It might have been cracked for a year or two as I never remove the battery tray. Battery is a silver Cadmium AGM . Only remove it if we know we are not going out for two months.

 

[audiorob]

Maybe using some strips of self adhesive trunking like this

Deta TTE uPVC White Self-Adhesive Mini Trunking 25mm x 16mm x 2m - Screwfix

Order online at Screwfix.com. Manufactured from high impact, robust heavy gauge uPVC. FREE next day delivery available, free collection in 1 minute.

www.screwfix.com

would lift the battery tray sufficiently to avoid the clash in the corners - would be lighter and maybe preferable to any timber within the battery box?

 

[Hutch]

Maybe using some strips of self adhesive trunking like this

Deta TTE uPVC White Self-Adhesive Mini Trunking 25mm x 16mm x 2m - Screwfix

Order online at Screwfix.com. Manufactured from high impact, robust heavy gauge uPVC. FREE next day delivery available, free collection in 1 minute.

www.screwfix.com

would lift the battery tray sufficiently to avoid the clash in the corners - would be lighter and maybe preferable to any timber within the battery box?

Good idea, I have some in the garage, I will check if it is strong enough. I have found a plastic putty which I can reinforce with mesh to reform the corner and seal the crack.

 

[Hutch]

Well after not being able to get up to the caravan due to illnesses, ( Detached Retina) and a couple of operations. I have worked out why the battery box cracked.
The battery tray only goes into the battery box one way, the front of the tray is rounded and the back is square, When the battery sits in the tray it doesn't allow the tray to go fully back . So my fault, NOT paying attention to which way round the trays go.

 

[Hutch]

Now to work out a suitable repair.

 

[otherclive]

I used this to repair an A frame fairing corner and a damaged sink unit in the caravan.

https://cpc.farnell.com/fiberfix/39201gbr/repair-flex-patch-3pk/dp/SA03788?mckv=s_dm%7Cpcrid%7C224653346133%7Ckword%7C%7Cmatch%7C%7Cplid%7C%7Cslid%7C%7Cproduct%7CSA03788%7Cpgrid%7C50784644841%7Cptaid%7Cpla-1688693361078%7C&CMP=KNC-GUK-CPC-SHOPPING-945678466-50784644841-SA03788&s_kwcid=AL!5616!3!224653346133!!!network%7D!1688693361078!&gad_source=1&gclid=EAIaIQobChMI1-6RkZ6ShQMVqJRQBh3G0wiCEAQYBiABEgJesvD_BwE

 

[Hutch]

Thanks OC, that looks like a handy repair, without have to mix messy resins.

 

[otherclive]

Thanks OC, that looks like a handy repair, without have to mix messy resins.

They also make a tape option too.

 

[GaryB]

Glad it's not just me then! A few years back I couldn't understand why the battery tray wouldn't fit the new caravan and cursed and swore several times before I looked down on the top of the tray and noticed how it tapered in one way! Even so, the battery boxes aren't particularly "generous" and like you I have to balance it on the step to connect it up and then slide it in from the top of the step.

 

[otherclive]

Glad it's not just me then! A few years back I couldn't understand why the battery tray wouldn't fit the new caravan and cursed and swore several times before I looked down on the top of the tray and noticed how it tapered in one way! Even so, the battery boxes aren't particularly "generous" and like you I have to balance it on the step to connect it up and then slide it in from the top of the step.

Rather than all the unreliable gizmos makers could fit a decent slide out battery tray.

 

[Mel]

Never ever looked at ours! Will check it out next time we are away.
Thanks Hutch; hope you get it fixed
Mel

 

[Hutch]

If you enlarge the photo you can see the square end of the tray to the left and the rounded end to the right.