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I have had quite a few people ask me questions about the battery box enlargement project I finished a couple of months ago, and since I have a couple of minutes of down time at work I figured I would post a thread about it. I enlarged the battery box area of my 2002 super sport from its existing size of being able to hold a 24 battery (under the port hind seat cushion) to being able to hold a 24 (starting) and two 27s (house/auxillary batteries) to better handle to demands of four ballast pumps, three amps, stereo, lights, etc.
1. The first thing I did was lift up the carpet. I was actually able to lift it up from under the gunnel (under the black rubber border) and reflect it back towards the bow. 2. Then I measured about 50 times to make sure that I had the right dimensions for the three batteries, and wouldnt end up outside the hind seat area.
3. Then pucker time! I used a multi-tool (the new dremel cutting tool works great, or you can pick up one at Harbor Freight, aka Man's Disneyland) to cut through the floor in a rectangle. I allowed for the extra space for the insert (see next few steps) and the reglass.
4. After, removing the fiberglass floor, i took a hand saw and started removing the foam. I removed it down to the hull.
5. In order to give a bit more support, I built a wood box that fit in the cut out that I eventually glassed over. I connected a drain into the bilge using 1/2 inch PVC pipe so water wouldn't pool in the box area around the batteries.
6. Before I glassed in the box, I drilled several holes in it and injected expanding foam to take up the space in between the hull and the wood. This (i believe) will give it even more support and keep it from shifting. The small amount of foam which came out the holes as it expanded and set was sanded away.
7. Since I wanted to make it look as stock as possible I glassed the bottom and the sides with several layers of 6 oz. cloth, then covered with three layers of resin pigmented black.
8. Once I made sure that all three batteries fit (actually I did this through each step), I cut the carpet out to fit and glued it back down to the floor.
9. I secured the batteries (I didnt think far enough ahead to put completed pictures on my computer but I will this weekend), added the perko switch and I was done!
Hopefully this helps. it really was not difficult once you got past the fact that you were cutting a hole in your floor. Please let me know if you have any questions.
Eric
1. The first thing I did was lift up the carpet. I was actually able to lift it up from under the gunnel (under the black rubber border) and reflect it back towards the bow. 2. Then I measured about 50 times to make sure that I had the right dimensions for the three batteries, and wouldnt end up outside the hind seat area.
3. Then pucker time! I used a multi-tool (the new dremel cutting tool works great, or you can pick up one at Harbor Freight, aka Man's Disneyland) to cut through the floor in a rectangle. I allowed for the extra space for the insert (see next few steps) and the reglass.
4. After, removing the fiberglass floor, i took a hand saw and started removing the foam. I removed it down to the hull.
5. In order to give a bit more support, I built a wood box that fit in the cut out that I eventually glassed over. I connected a drain into the bilge using 1/2 inch PVC pipe so water wouldn't pool in the box area around the batteries.
6. Before I glassed in the box, I drilled several holes in it and injected expanding foam to take up the space in between the hull and the wood. This (i believe) will give it even more support and keep it from shifting. The small amount of foam which came out the holes as it expanded and set was sanded away.
7. Since I wanted to make it look as stock as possible I glassed the bottom and the sides with several layers of 6 oz. cloth, then covered with three layers of resin pigmented black.
8. Once I made sure that all three batteries fit (actually I did this through each step), I cut the carpet out to fit and glued it back down to the floor.
9. I secured the batteries (I didnt think far enough ahead to put completed pictures on my computer but I will this weekend), added the perko switch and I was done!
Hopefully this helps. it really was not difficult once you got past the fact that you were cutting a hole in your floor. Please let me know if you have any questions.
Eric
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