CC DS 4-12v to 6-8v conversion

[cgtech]

Here is an overview of a decent (in my opinion) DS 4-12v to 6-8v conversion with adequate hold-downs, and no cheezy lumber or other bs.

Materials needed-

- 4 of your original hold down rods for reuse
- 2 of your original plastic hold downs for reuse
- 4 standard DS 8v hold down rods w/ nuts and washers (i used yamaha G22e rods, i had them on hand)
- 2 DS 8v plastic hold downs
- 2x 15" lenghts of (2"x2"x1/8" aluminum angle)
- 4x 13.5" lenghts of (2"x2"x1/8" aluminum angle)
I used a chopsaw with 1/8" kerf, so my angle may have been slightly shorter.
Angle aluminum was available at local hardware store.
- 12x 1/8" pop rivets
- 6x 8v batteries of your preference.
- your original cables for reuse (or new cables for 12v DS)
- will also need 2 additional cables (marked red)

Tools Needed-

- air hammer with chisel far easier, or hammer & chisel
- chopsaw or hacksaw for cutting aluminum angle
- rivet gun for installing rivets
- 13/64" or 1/8" drill bit for rivet holes
- drill bit for hold down rod holes, not fussy, just bigger than hold down rods
- drill
- cable & ends for 2 new cables

Steps-

- remove 12v batts and extensive cleaning
- (air hammer chisel) remove 4x spacer brackets (circled green)
- (air hammer chisel) remove 2x support brackets (circled blue)
- use 13/64" bit for rivet holes on next 2 steps
- install 2x each outer battery bay, 13.5" support brackets with 7.5" spacing inside to allow 1 battery to rest inside.
- install 2x center battery bay 15" support brackets with roughly 10.5" spacing from center bracket to allow 2 batts to rest on each side of center bracket.
- set a battery in tray, mark locations for new hold down rods holes on center brace and new (15") brackets.
- remove battery, drill new holes for hold down rods.
-Install batteries, hold down rods, and cables.

I configured the batteries this way for my convienince in cable routing (i had to cut out a corroded portion of main positive cable). You may configure your batts however you like. The 4x 12v ds has no voltage reducer, i used a simple method of automotive resistor wire to reduce voltage, a dc/dc reducer would have been nicer, but i didnt have one.