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General Category >> Rubber Side Down! >> Mini Battery Box, Building, and Relocation
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Message started by uigiroux on 10/13/13 at 00:03:48

Title: Mini Battery Box, Building, and Relocation
Post by uigiroux on 10/13/13 at 00:03:48

Hello,
So I want to do a cafe/brat style build with my Savage and definitely will be removing the stock airbox for a cone filter. I've seen many great ideas for where to put the battery (I was thinking on the swing arm on the muffler bracket, but also would be open to just having a small box that fits where the stock one already does. I've found a few people who could fabricate me a box, but my funds are low and I was hoping someone could help me figure out how to build one of my own, maybe just out of some thin 6061 grade sheet metal. Anyone have some way you can help me out here???

Title: Re: Mini Battery Box, Building, and Relocation
Post by HondaLavis on 10/13/13 at 08:42:41

Here is the tech on the mini-battery install by boule'tard: http://suzukisavage.com/cgi-bin/YaBB.pl?num=1259644714

I used the same strap steel that he used. My welding skills weren't refined (first time and all) so instead of trying to weld threaded steel to the bottom, I inserted two carriage bolts through the holes and I used nuts and a washer with an inner diameter larger than the square key on the carriage bolt to tighten it down, effectively punching the square shape into the metal. I also only created three sides. I did it the hard way: I welded three L-shaped pieces together. You could make a U shape and simply weld an additional L piece onto it to make the front of the bracket. The back part I left open, and I use zip ties to hold it in.

A couple of notes:

-Clearance space is very limited. You need to be precise! If You use the carriage bolt method, you will have to grind the tops of them down pretty far.

-In the article, Boule'tard had to extend his wiring. If you don't want to do this, you can rearrange a few things and use the stock wiring. I mention in the article where I moved my ground wire to.

-You don't need any fancy cutters or angle benders like he used. All I needed was a vice, measuring tool, sharpie, and a BFH!

-To protect your battery from vibration, I recommend wrapping in strips of rubber. The easiest source I could find were bicycle inner tubes! You can slip them on over the posts of your bracket or wrap your battery... The only limit is your imagination ! :D

Hope this helps.