- Action: To Do List item A0214 - Clean, sand, and apply paint to starboard quarter birth area before battery installation.
- Action: To Do List item A0215 - Apply coat of epoxy and paint to wooden battery box.
- Action: To Do List item A0216 - Determine method to secure wooden battery box to boat structure.
- Action: To Do List item A0217 - Determine method to secure engine start battery to boat structure.
- Completed: 8 November 2017
- Cost: $168.02
Prior to installation of the battery box with new AGM batteries, the area below and around the battery box needed to be cleaned up. To facilitate this, most of the cables and wiring were removed first. Then the area was lighted sanded with 80 grit sand paper to loosen up years of layers of accumulated dirt/crud, which was then vacuumed clean. The area was then wiped clean with rags soaked in isopropyl alcohol. Additional wood supports were added and all exposed wood surfaces were coated with West System 105 Epoxy Resin with 206 Slow Hardener (~$25.00).
With the area cleaned-up and prepared, it was painted with Interlux InterProtect HS Epoxy primer (~$20.00), which is also recommended as a bilge paint. A hole was drilled in the low point of each section to allow a path for water to drain into the bilge.
As the pictures below depict: The original battery box wood surfaces were not protected by a layer of paint, the batteries were not secured down, and there was no air ventilation path. The battery box and cover lid were removed from the boat to work on. All surfaces were sanded with 80 grit sand paper to remove traces of mold/mildew plus general dirt/crud. The inside top of the battery box lid had excess contamination of black sulfur residue and had a distinct bad smell to it - this was a result of battery acid/fumes leaking from the defective GEL batteries. After sanding, the wood surfaces were wiped clean with isopropyl alcohol. A patch of fiber glass cloth (~$3.00) was cut to cover the bottom inside of the box and extend up the sides approximately three inches. The cloth was then epoxied down and the entire box, inside and out, was coated with epoxy (~$10.00). Three inch circular holes were drilled in the box for ventilation and the exposed wood was also coated in epoxy. The box and it's lid was then painted with Interlux InterProtect HS Epoxy primer (~$10.00). The new AGM batteries were placed in the box for a fit check, but it was discovered that they could shift position as there was additional free space around the base of them. Wooden spacers were fabricated and secured in the bottom of the box with fiber glass cloth and epoxy. Additional notches were cut on the top edge of the box to allow the use of web straps to secure the batteries. A final coat of Interlux InterProtect HS Epoxy primer paint (~$10.00) was applied. Metal vents ($22.40) were installed over the 3-inch circular holes. Two metal pad eyes ($11.56) were installed and adjustable belts (~$15.00) made of webbing rate at 7,000 pounds break strength were constructed. The finished box was fit checked in the starboard quarter birth area.
To hold the engine start battery, a flat tray of wood was constructed, which was also epoxied and painted (~$10.00). The wood tray was then secured to the wood supports underneath it with large lag screws. Pad eyes ($11.56) and web straps ($7.50) were installed to firmly secure the battery in-place to the wood tray.
The battery box was also secured to the wood supports underneath it with large lag screws (~$12.00). The new AGM batteries were installed and secured in-place with web straps. The web straps were positioned to avoid covering any of the battery over-pressurization vent holes.
