I am going to install the Odyssey PC680 battery in the RV-7A. DWG 31A shows Van's battery box kit and it is made from steel. I searched the internet and found and aluminum box made for the PC680. I thought it would work, but the flanges already had holes in it for mounting and do not line up with the firewall stiffener as called out in the drawing. I decided to cut the flanges off and rivet on 3/4" x 3/4" .063 aluminum angle that I could match to the drawing. I cut the flanges off with my pneumatic cutoff wheel and deburred the edges. I also cut 3/8" off the height of the box using my band saw so I could use the retaining bar thats in the drawing. I cut 2 lengths of aluminum angle to 8 3/4" long. I marked 3" on each angle and used a 45 degree square to mark a wedge cut. This way I could bend the angle into a 90 degree to add strength. I made the cut in my band saw and deburred the edges. I clamped the angle in my wood vise and hand bent the 90. I trimmed the ends to get the perfect. I marked the angle for the 6 vertical box rivets and 3 horizontal rivets. I match drilled all 18 holes and deburred. The retaining bar is made from aluminum stock 1 1/2" x 8 28/32" and .125" thick. I cut the bar to length and cut the radius in both ends and polished the edges on my scotch brite wheel. I marked the location of the 6 lightening holes that are to be 3/4" and also marked the AN3 bolt hole locations. I will match drill the holes later to the nutplates on the battery box angles. I did some test fitting on the firewall and the fit is good. I disassembled the battery box and cleaned it. I will take it and the retaining bar in to have it powder coated.
