My battery box doesn’t line up

[nohoflyer]

I aligned the left side of the box with the correct rivet on the brace but now I’m a few mm off on the right. Ugh.

How snug is the PC680 in that box? Maybe I can cut it down a bit (shrink the box).

 

[wirejock]

My battery was snug.
My box was off by a hair too. I enlarged the hole in the steel battery box just a little. I recommend using floating nutplates if you do the same. Makes it easier to install. I made three studs with slotted ends from old bolts. One stud in each nutplate. Push the box into place. The studs hold it aligned while you climb inside. Spin on a couple wing nuts to hold it. Remove a stud and replace with the bolt. Repeat.

Battery box modification I recommend...
Cut the front off the box. Install hinges plus a 3-16"-1/4" of depth. use the wider hinge material. Makes it much easier to R&R a battery. I fabricated a "T" shaped spacer from baffle material. It takes up most of the space between the battery and firewall and also protects from an inadvertent short from the positive terminal.

 

[bjdecker]

The box is actually from an Odyssey PC680MJ (Metal Jacket). It will fit like a glove.

And review the plans again -- it seems that you've deviated a bit, sequence-wise as well as parts/construction (e.g. extra platenut, lightening holes)

 

[RV7 To Go]

Battery box modification I recommend...
Cut the front off the box. Install hinges plus a 3-16"-1/4" of depth. use the wider hinge material. Makes it much easier to R&R a battery. I fabricated a "T" shaped spacer from baffle material. It takes up most of the space between the battery and firewall and also protects from an inadvertent short from the positive terminal.

+1 on the mod. It makes it much easier to get the battery out later when the mount and engine etc are in place.

 

[nohoflyer]

The box is actually from an Odyssey PC680MJ (Metal Jacket). It will fit like a glove.

And review the plans again -- it seems that you've deviated a bit, sequence-wise as well as parts/construction (e.g. extra platenut, lightening holes)

View attachment 103221

Yea my lightening holes are a joke. And you’re right, I have too many nutplates. Jeez.

 

[lr172]

I aligned the left side of the box with the correct rivet on the brace but now I’m a few mm off on the right. Ugh.

How snug is the PC680 in that box? Maybe I can cut it down a bit (shrink the box).

Pretty snug, especially if powder coated.

 

[PaulvS]

+1 for making the box bigger per @wirejock suggestion

I found that an alternative brand battery to Odyssey PC680 (Fullriver, a good battery) was slightly larger, like 1/8", and it would not fit into the box without enlarging the box.

 

[gregmc]

Another option, if you decide to re-do yours...
I'm not flying yet, but having read of dramas with tight fitting batteries I decided to install the RV-14 battery box. Much lighter and the Full River battery fits in easy.

 

[nohoflyer]

I will remove a few of the unnecessary bolts on the left and see if I can nudge it into position. I also ordered the battery (PC680) and play with the fit.