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art_lessing
Samba Member
Joined: February 20, 2014
Posts: 157
Location: Sacramento
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 Posted: Mon Mar 19, 2018 3:47 pm Post subject: Battery trays are too expensive soooo..... |
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So I made my own!!!
its a tad small though
...Actually I was just noticing how pricey they are, 100+ bucks and decided to give a scale model an attempt at fabrication
This was really easy at this size, I don't anticipate 22-20 gauge being much harder.
I have one question to any fabricator people out there, how does one fabricate a channel for seals? |
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c21darrel
Samba Member
Joined: January 22, 2009
Posts: 8237
Location: San Dimas
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32989
Location: Reading Pennsylvania
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iowegian 
Samba Curmudgeon
Joined: February 16, 2005
Posts: 9954
Location: Somewhere between Dubuque and Keokuk
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| Posted: Mon Mar 19, 2018 4:56 pm Post subject: Re: Battery trays are too expensive soooo..... |
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| c21darrel wrote: |
| LOL, that was great! It looked small but i wasn't sure til i read your post. |
I thought "where did he get those YUUUGE scissors?" |
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Mellow Yellow 74
Samba Member
Joined: October 14, 2014
Posts: 1615
Location: Sydney, Australia
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| Posted: Mon Mar 19, 2018 8:05 pm Post subject: Re: Battery trays are too expensive soooo..... |
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| art_lessing wrote: |
| This was really easy at this size, I don't anticipate 22-20 gauge being much harder. |
Unless you have access to a folding brake, bead roller and shrinker/stretcher it will be much harder. Even with these you will probably take longer in your time than $100 is worth and turn out worse than a bought one unless you know what you are doing.
By all means do it for the feeling of achievement in doing it yourself but if you are only trying to save $100 do yourself a favour and buy a repro one. I have bought and made a lot of panels as part of my resto and my conclusion is that if there is a repro part available, you are better off buying instead of making your own except for very simple patch pieces.
_________________
1962 Karmann Ghia
1974 Deluxe Microbus
1985 Caravelle (Vanagon) |
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J1
Samba Member
Joined: February 10, 2014
Posts: 707
Location: Bottom left
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| Posted: Mon Mar 19, 2018 8:31 pm Post subject: Re: Battery trays are too expensive soooo..... |
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| Mellow Yellow 74 wrote: |
| Unless you have access to a folding brake, bead roller and shrinker/stretcher it will be much harder. Even with these you will probably take longer in your time than $100 is worth and turn out worse than a bought one unless you know what you are doing. |
Agreed. Here’s one of my first fabrication attempts and it took WAY longer than expected, for a lesser result of course than a purchased item. I believe this was 18g. https://www.thesamba.com/vw/forum/viewtopic.php?p=7677793#7677793
I’ve seen examples here of folks doing some pretty amazing fabrication without “real” tools and if you have the patience and skill, I’m sure we’d all love to see it. But be prepared to be brutish for the wrestling match, while also delicate to finesse stubborn pieces of metal.
I actually have to work on my battery tray too and I will for sure be buying one. Well, unless you provide some inspiration!
_________________
1971 Ghia coupe. Assume I know nothing and you'll be pretty darn close to the truth. |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32989
Location: Reading Pennsylvania
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kman
Samba Member
Joined: November 04, 2005
Posts: 739
Location: Michigan
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| Posted: Tue Mar 20, 2018 6:11 am Post subject: Re: Battery trays are too expensive soooo..... |
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| Mellow Yellow 74 wrote: |
| art_lessing wrote: |
| This was really easy at this size, I don't anticipate 22-20 gauge being much harder. |
Unless you have access to a folding brake, bead roller and shrinker/stretcher it will be much harder. Even with these you will probably take longer in your time than $100 is worth and turn out worse than a bought one unless you know what you are doing.
By all means do it for the feeling of achievement in doing it yourself but if you are only trying to save $100 do yourself a favour and buy a repro one. I have bought and made a lot of panels as part of my resto and my conclusion is that if there is a repro part available, you are better off buying instead of making your own except for very simple patch pieces. |
I agree with this mostly But for $100 this piece is pretty easy. I've had a lot of practice by now but I could do it with hand tools in under an hour, Cut a blank form out of oak and it will make the bends much easier, especially the curved section. Buy a shrinker/ stretcher and you won't have to notch the curved section at all, though there are other ways to shrink and strecth this is easiest.
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71 vert build. http://www.thesamba.com/vw/forum/viewtopic.php?t=572951&highlight=dead |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32989
Location: Reading Pennsylvania
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Evil_Fiz
Samba Member
Joined: May 06, 2011
Posts: 1111
Location: Jacksonville, FL
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| Posted: Tue Mar 20, 2018 5:01 pm Post subject: Re: Battery trays are too expensive soooo..... |
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^^^ X2. My hobby hours are paying me dividends in the form of: escape from the day-to-day, satisfaction in personal accomplishment, and granting me new knowledge that only comes from doing instead of buying.
...we're all in this together,
Emil
_________________
“…It's not just about what's interesting. It's also about what's helpful, and it's helpful even if it helps just one other guy working on a Ghia.”
kiwighia68
See my build on TheSamba at:
The K_R_A_K_E_N_N : a 70 Ghia Convertible reinterpreted |
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art_lessing
Samba Member
Joined: February 20, 2014
Posts: 157
Location: Sacramento
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| Posted: Tue Mar 20, 2018 8:34 pm Post subject: Re: Battery trays are too expensive soooo..... |
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| Yep...I am in over my head but what a better way to learn. And save a hundred bucks plus labor for each side. That being said, I figure since this is my first body repair, it's a perfect starting point. I am not skilled to do any butt welds so body panels are out. This section has no complex curves so it feels like I can do it with basic tools. Hammers sheet metal pliers, chisels ect. My plan is to make a paper template of the rotted panel before de-welding it and then add a seam allowance for the flanges. Then since my battery is on the other side, I will cut a hole in my new panel that will hold a six pack. I am going to need it for when I tally up all the missing tin I do have to purchase... |
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c21darrel
Samba Member
Joined: January 22, 2009
Posts: 8237
Location: San Dimas
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NOVA Airhead
Samba Member
Joined: July 20, 2005
Posts: 5225
Location: Richmond, VA
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| Posted: Thu Mar 22, 2018 7:47 am Post subject: Re: Battery trays are too expensive soooo..... |
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| art_lessing wrote: |
...I don't anticipate 22-20 gauge being much harder.
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What?! You mean you are not going to use an old license plate or street sign? After seeing so many cars I thought this was the standard material for floor pan and battery tray repairs!
_________________
Ghia Owner Emeritus |
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kman
Samba Member
Joined: November 04, 2005
Posts: 739
Location: Michigan
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| Posted: Thu Mar 22, 2018 8:08 am Post subject: Re: Battery trays are too expensive soooo..... |
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| NOVA Airhead wrote: |
| art_lessing wrote: |
...I don't anticipate 22-20 gauge being much harder.
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What?! You mean you are not going to use an old license plate or street sign? After seeing so many cars I thought this was the standard material for floor pan and battery tray repairs!
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or ductwork sheet metal with rivets?
Even 18 gauge mild steel isn't too bad to work with.
_________________
71 vert build. http://www.thesamba.com/vw/forum/viewtopic.php?t=572951&highlight=dead |
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art_lessing
Samba Member
Joined: February 20, 2014
Posts: 157
Location: Sacramento
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| Posted: Thu Mar 22, 2018 8:36 am Post subject: Re: Battery trays are too expensive soooo..... |
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I was considering it but once I unfastened the PO metal bandaid I found this
Then upon poking around I found that they tried to cover it with fiberglass
Some of the rear tray is bad too, but I did notice that the metal up by the battery fastener is still solid! As well as the under support beam
It looks like a tweaker started to cut into it and gave up...
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kiwighia68
Samba Member
Joined: October 20, 2013
Posts: 2943
Location: Auckland, New Zealand
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| Posted: Thu Mar 22, 2018 11:18 am Post subject: Re: Battery trays are too expensive soooo..... |
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| djkeev wrote: |
... This is a Hobby...
Dave |
It's also therapy that keeps the ghosts of aging, boredom and self-doubt at bay. Peace of mind that money can't buy.
By the way, there's also the wow factor. Every time you look at the completed job you go, "Wow, I did that all by myself!"
Priceless.
_________________
Festina lente - hasten slowly
1968 Ghia named Emiko
Resto completed Dec 2015 |
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anthracitedub
Samba Member
Joined: June 20, 2007
Posts: 3241
Location: Michigan
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| Posted: Thu Mar 22, 2018 6:27 pm Post subject: Re: Battery trays are too expensive soooo..... |
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| Having a creative hobby is one of the main steps in being a healthy individual. |
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xzener
Samba Member
Joined: June 03, 2006
Posts: 1778
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| Posted: Thu Mar 22, 2018 7:59 pm Post subject: Re: Battery trays are too expensive soooo..... |
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| art_lessing wrote: |
It looks like a tweaker started to cut into it and gave up...
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Was this the look on your face when you ripped off the band-aid??
_________________
My 70 beetle was totaled Now to build the Ghia I always wanted. Rest in peace Ruby, I will miss you. Hello <insert Ghia name here>! |
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art_lessing
Samba Member
Joined: February 20, 2014
Posts: 157
Location: Sacramento
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| Posted: Thu Mar 22, 2018 8:42 pm Post subject: Re: Battery trays are too expensive soooo..... |
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| Yep... I found that the apron bracket support ( where do I find those?) is not attached, the other one is missing, the bumper support metal has lost the top lip on places, there is a weird seal/gasket on the tail light section of the battery tray, is the battery tray even attached to the body? the suport for the rear engine shelf is not attached... that's the one under the curved portion of the shelf where it meets the battery tray, I only hAve right sided tin snips and the metal is almost as thin as tin foil even on the good parts.....what the hell am I doing here....? |
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Mellow Yellow 74
Samba Member
Joined: October 14, 2014
Posts: 1615
Location: Sydney, Australia
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| Posted: Thu Mar 22, 2018 9:15 pm Post subject: Re: Battery trays are too expensive soooo..... |
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| kiwighia68 wrote: |
| Every time you look at the completed job you go, "Wow, I did that all by myself!" |
I have a friend who renovated his house and installed down lights throughout. His wife proudly told me that he did it himself but he is not the most handy of people so I queried this. What she meant was that he told the electrician where to install the lights all by himself.
_________________
1962 Karmann Ghia
1974 Deluxe Microbus
1985 Caravelle (Vanagon) |
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