Couldn't ya put a paint-cutting washer between the relay case and the
chassis? An outside-star lock washer will dig its little pointy teethy
things right into the metals. Properly-torqued, it will be a gas-tight
connection.

Like this guy:

http://product-image.tradeindia.com/00119865/s/0/Star-Washer.jpg

--
Mike "Rocket J Squirrel" Elliott
84 Westfalia: Mellow Yellow ("The Electrical Banana")
74 Utility Trailer. Ladybug Trailer, Inc., San Juan Capistrano
Bend, OR
KG6RCR

On 8/25/2009 1:12 PM mark drillock wrote:

> Not bad, seen much worse. The hot tip is to drill out the rivets that
> hold that POS Westy sealed lid bracket to the otherwise normal battery
> box so you can get batteries in/out without deforming the box and so
> there is more room for the cables. Throw the POS away and then get a
> regular lid with hinge that will attach to the existing small holes in
> the edge.
>
> One other thing, that 3 wire type of relay is using it's metal case for
> the coil ground so it may not work reliably unless you put a wire with
> ring terminal under one of it's bolts and ground the other end up where
> you can see it, like at the main battery ground.
>
> Mark
>
> neil N wrote:
>> Hi all.
>>
>> Click on the slide show to view scintillating comments. <grin>
>>
>> http://picasaweb.google.com/musomuso/AuxBatteryWireInstall#
>>
>> I still need to install a proper fuse panel, (though the inline fuses
>> will be fine), but I'm looking forward to trying all this stuff out.
>>
>> Neil.
>>
>>
>> --
>> Neil Nicholson '81 VanaJetta 2.0 "Jaco"
>>
>> http://tubaneil.googlepages.com/
>>
>> http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines
>>
>>
>