battery tray corrosion

[gornoman]

I think I'm gonna be sick........

[dgjks6]

since we are looking at my degraded battery tray - in the picture posted above there is an orange wire that was connected to nothing. Anyone have any idea what that went to?

And I know it looks bad, but all I could think of when taking the batteries out is how lucky I am that the batteries did not fall out while the kids were driving.

[impalass88]

When you get this repaired spray the whole frame assembly with truck bed liner. Rust-O-Leum and some others make this in a spray can. It holds up real well to battery acid and should prevent this from happening again.

[dgjks6]

So I got most of the corrision off and I am in the process of fixing the supports. I found some wood between the edge of the battery tray and the side of the golf cart body.

Is this supposed to be there? Do I need to replace it?

[scottyb]

no on the wood ......

[gsf35099]

Originally Posted by dgjks6

So I got most of the corrision off and I am in the process of fixing the supports. I found some wood between the edge of the battery tray and the side of the golf cart body.

Is this supposed to be there? Do I need to replace it?

dgjks6,
I had the same problem from a cart that I bought. I did like the gent's are saying here. I cleaned like crazy using neutralizer and grinding wheel and wire brush. Then I cut out the old aluminum and riveted in new aluminum angle pieces. I didn't quite have the amount of deterioration on the center 2 battery compartment that you have. Like scottyB said, you will need to find a good way to repair that one as well.

Don't forget to drill holes for the battery tie downs.. I forgot to drill the holes before I riveted the new pieces in and it was a little bit of a pain to drill them afterward.

Here is my before and after pic's.

[OLD MEC]

The extent of damage looks as though you need to clean it up good ( as Scottyb says )and ( weld ) in new correct guage of aluminum angle? I saw a new aftermarket replacement Club Car frame that a non dealer was installing and it looked like it was about 1/4" material around battery area? Looks like your cross member is damaged beyond repair and just riveting or bolting I dont think will support the 140 plus pounds of battery weight and give the needed structural support needed?
This has been caused by previous owners neglect and nothing is going to stop this kind of damage unless the present owner does a good job of maintenance and does not over fill batterys? NOTHING REPLACES REGULAR BATTERY SERVICING AND CLEANING.
In my area near the ocean many different brands of cart owners are having a pick up spray bed liner material ( RHINO FLEX, ETC MATERIALS ) added that helps in many ways.

[scottyb]

Originally Posted by OLD MEC

The extent of damage looks as though you need to clean it up good ( as Scottyb says )and ( weld ) in new correct guage of aluminum angle? I saw a new aftermarket replacement Club Car frame that a non dealer was installing and it looked like it was about 1/4" material around battery area? Looks like your cross member is damaged beyond repair and just riveting or bolting I dont think will support the 140 plus pounds of battery weight and give the needed structural support needed?
This has been caused by previous owners neglect and nothing is going to stop this kind of damage unless the present owner does a good job of maintenance and does not over fill batterys? NOTHING REPLACES REGULAR BATTERY SERVICING AND CLEANING.
In my area near the ocean many different brands of cart owners are having a pick up spray bed liner material ( RHINO FLEX, ETC MATERIALS ) added that helps in many ways.

I agree with the Old South Texas Mechanic on the structural note

Consider the weight and the fact that every bump makes the batteries act like a big hammer.... weld in repairs

[Frizbgolf]

any local ace hardware will sell aluminum angle in 60" lengths also

[cdb770]

Originally Posted by OLD MEC

The extent of damage looks as though you need to clean it up good ( as Scottyb says )and ( weld ) in new correct guage of aluminum angle? I saw a new aftermarket replacement Club Car frame that a non dealer was installing and it looked like it was about 1/4" material around battery area? Looks like your cross member is damaged beyond repair and just riveting or bolting I dont think will support the 140 plus pounds of battery weight and give the needed structural support needed?
This has been caused by previous owners neglect and nothing is going to stop this kind of damage unless the present owner does a good job of maintenance and does not over fill batterys? NOTHING REPLACES REGULAR BATTERY SERVICING AND CLEANING.
In my area near the ocean many different brands of cart owners are having a pick up spray bed liner material ( RHINO FLEX, ETC MATERIALS ) added that helps in many ways.

Actually if you use the correct cherrymax structural rivets in the construction it can be quite sturdy and hold the 140 lbs easily. Go to Fastenal.com and search structural rivets/fasteners and make sure to use enough in a pettern of at least four to five in a domino pattern to spread out the load on each end.

note the tensile strength of the rivets is 1200 lbs.

Diameter 3/16"
Head Button
Head Diameter 0.355" - 0.400"
Length 0.416"
Specification ASME/ANSI B18.1.1
Type Structural Blind Rivet
Drill Size #11
Head Height 0.090"
Hole Size 0.194" - 0.204"
Grip Range 0.052" - 0.250"
Material - Body/Mandrel Stainless Steel/Stainless Steel
Tensile Strength 1200 lb
Series SSB6-4SKL
Shipping Weight 0.0080 lbs.