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Kupe's Zodiac 650B
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Date:  6-11-2015
Number of Hours:  1.50
Manual Reference:  
Brief Description:  Battery Box Fitting

Brought the battery box parts up from the basement. The battery is attached to the engine side of the firewall on the passenger side. The assembly consists of a narrow shelf the battery rests on (an extruded aluminum L-angle) and a wide aluminum strap that keeps the battery tight against the firewall. To protect the battery from hard surfaces and to reduce sliding/vibrating, the interitor of the battery assembly is lined with cork.

First, I set a 5 rivet line in the flange of the lower shelf and drilled it out to pilot hole size. After measuring for the correct position, I match-drilled through the shelf flange into the firewall. After cleaning up all of the parts (label removal, filing, sanding), I attached cork strips to the top of the shelf, interior of the metal strap, and against the firewall. I added a pilot hole to the center of the flange on each end of the strap. I reattached the corked shelf to the firewall, centered the battery on the shelf, wrapped the metal strap around the battery and match-drilled the holes in the strap into the firewall where they will evenually house nut plates for removable screws.

With a little extra time before work, I positioned and pilot-drilled two holes to attach the solenoid to the firewall. Satisfied with the placement of the holes, I updrilled them to 1/4" for the AN4 attach bolts. I then cleaned up the holes and attached the solenoid to the firewall with nuts and bolts.
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Battery resting on shelf with metal strap temporarily attached to the firewall with clecos.

Battery resting on shelf with metal strap temporarily attached to the firewall with clecos.

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Battery from below (shelf visible) and installed solenoid.

Battery from below (shelf visible) and installed solenoid.

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The firewall is beginning to fill up.

The firewall is beginning to fill up.

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