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Old 10-01-2018, 09:38 AM   #1
kfortier5
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Default Battery Tray Corrosion -- Replace or not?

I've read some prior posts on replacing the aluminum angles in the tray, so I have a decent understanding of the process. My gut tells me some of mine need to be replaced... but I don't have a pop rivet gun, so i'd like to avoid replacement, if possible. Can anyone comment on the condition of the pieces in these two photos? The corners are in decent shape, but the middle towards the hold down rods looks pretty bad.

If you do recommend replacement, can you share your thoughts on removing the cross sections? They are welded on top of the frame, so I'm wondering if anyone has had experience prying them off instead of cutting them out.

Thanks, as always.

PS: I inherited this cart and plan to take much better care of it to prevent this mess in the future!
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Old 10-01-2018, 09:44 AM   #2
BBBHC
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Default Re: Battery Tray Corrosion -- Replace or not?

If it were me, I'd replace them. You may get by for a while as is, but I wouldn't trust it.

You could drill and bolt the new angle in, instead of rivet.
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Old 10-01-2018, 10:51 AM   #3
kfortier5
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Default Re: Battery Tray Corrosion -- Replace or not?

Thanks BBB. I've already hauled the batteries out, so I think you're right. Might as well do it.

For bolting, I guess i have to countersink so the batteries have a nice flat space to sit on. The angle is only 1/8" thick. So I need to find an aluminum bolt with a low-profile head.... any thoughts on that? Not seeing anything on the home depot site that would work. I'm new the world of specialty hardware, so not sure where to look.
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Old 10-01-2018, 11:21 AM   #4
hipower
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Default Re: Battery Tray Corrosion -- Replace or not?

Finding aluminum hardware could be an issue. I would use stainless, which is readily available.
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Old 10-01-2018, 01:46 PM   #5
mrgolf
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Default Re: Battery Tray Corrosion -- Replace or not?

If you can get your hands on a pressure washer I think it would clean things up pretty good. Then you'll know more about what you have. Be careful to keep the water out of electronics and switches.
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Old 10-01-2018, 02:46 PM   #6
BBBHC
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Default Re: Battery Tray Corrosion -- Replace or not?

Quote:
Originally Posted by hipower View Post
Finding aluminum hardware could be an issue. I would use stainless, which is readily available.
I agree with hipower, stainless will work with aluminum.
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Old 10-01-2018, 03:03 PM   #7
Fairtax4me
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Default Re: Battery Tray Corrosion -- Replace or not?

Yeah those need to be replaced.

I did a bunch a few years ago and I just cut them in the center with a sawzall, then twisted and pried the welds apart. To flatten down what was left of the welds I used small sanding disc on a die grinder.

I riveted mine back in, but if you don't have access to a riveter use stainless hardware.
If you use 3/16" aluminum you'll have more depth of material to be able to countersink the screw heads.
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Old 10-01-2018, 03:13 PM   #8
sunnydays
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Default Re: Battery Tray Corrosion -- Replace or not?

I am in the process of doing this right now. My battery tray had actually broken and the batteries were tipped in on each other and that's what stopped them from falling. We have a hardware supply store here that carries various metals and I actually found 1 1/2 by 1/8 inch thick aluminum angle. I cut them to length today and will weld them in tomorrow. As far as removing the old ones I just took a reciprocating saw and cut all the battery tray framework out. Then I used a air powered cut off wheel and cut the welds out best I could where it was attached to the frame. Lastly I used an air chisel in the grooves the cutoff wheel left and the metal popped right off. Just a matter of grinding the welds flat and ready to reassemble. Hope this helps. Make sure to get all your measurements and make yourself a diagram before dismantling.
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Old 10-01-2018, 05:26 PM   #9
scottyb
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Default Re: Battery Tray Corrosion -- Replace or not?

Welding the battery trays makes a good repair if you can get past the corrosion the just keeps coming into the weld from the dirty aluminum.
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Old 10-01-2018, 07:31 PM   #10
golf cart man
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Default Re: Battery Tray Corrosion -- Replace or not?

I bet a carriage bolt would sit flat enough to not cause any issues with the batteries sitting properly.
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