I find these battery cover posts hilarious!  That battery practically wedges in there!  Hold down straps?  Tip over issues?   

Bouncing around on the road?  PLEEZEEEEEEEEEE!

----- Original Message -----
From: developtrust
Sent: Friday, January 11, 2002 4:40 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: Aux Battery Cover

Jonathan

Here is the text of an email I got from Harald about how he made his battery
cover. I plan to make one also using his instructions. Good luck/

William Polowniak
1989 Vanagon GL
1988 Mercedes 300 SE

Hi William,
I don't know if my aux. battery installation is the best solution, but the
reason I installed it
that way is mainly because it's much easier to lift the battery in and out
with the battery handle.
Also this way I was able to install the battery hold-down bar to keep the
battery securely
in place, in case of flip-over accident or so it doesn't bounce around on
bumpy roads.
About the rivets, yes, I drilled them out. If one would want to, one could
screw the
original cover back in place.
The custom top: I laid it up from fiberglass. The fiberglass matting and
resin is
available in boating stores.
1) Make a male shape from different layers of wood.
Basically one piece of 3/4" plywood, and for the rear raised part, a piece
of 1 1/2" wood.
2) Make a rectangular flat box, open at the top, a little larger than the
male
battery cover shape.
3) Fill the rectangular flat box with plaster of paris.
4) Press the male battery cover shape into the plaster of paris. Let it
cure.
5) When the plaster of paris has hardened sufficiently, remove the wood
shape.
6) Now you should have a female form of the battery cover. Let it sit for a
few days to dry.
7) Follow instructions on the fiberglass mat and resin kit. Lay the
fiberglass mat in
the female form. Soak it with fiberglass resin. Let it cure. More layers
will make it stronger.
8) Separate the fiberglass cover from the female form.
9) You can buy some stretch automotive fabric to glue on the top of the
cover for the
finished look.
This description is somewhat simplified, but it gives you an idea of how I
made the cover.
You can get more info in boating stores, on how to lay up fiberglass.
About the isolator:
It says in the instructions with the Sure Power isolator to install it close
to the
alternator for best results.
Have a nice holiday and Happy New Year. Hope it helps a little.
Harald
'90 westy

You said
" I want to make a battery
> Cover like H&N's. I cannot raise them, so does anyone have an idea of . .
."> Jonathan R. Cooper
> Brzytwa, Quick & McCrystal
> 900 Skylight Office Tower
> Cleveland, OH 44113
> 216-664-6900 (voice)
> 216-664-6901 (fax)
> Cooper@BQMlaw.com