Battery Box Replacement

[Tawney1]

Its time to replace our battery boxes when new batteries arrive. The old boxes are in rough shape and are original Hatteras from 1985. Can anyone tell me how those boxes are affixed to the wood floor (which also has some rot), and the best way to remove them? Are they 5200'd in place or screwed to the floor, etc.? Anyone have experience removing the old ones?

Thanks,

Paul

 

[bostonhatteras]

when I redid my entire battery system I found the fiberglass boxes were attached via resin to the plywood shelf. no screws or any type of fastener other than the resin. one came off easily but the others needed a wide blade putty knife tapped between the box and the ply. they came out eventually but it was a pain in the ass. they were also reusable as I took a lot of care removing them. Those Rolls individual cell 8ds with their own box are awful tempting

 

[rmatt]

I replace my batteries and boxes this year. Elected to replace the two 8d with four series 31. The battery boxes were stuck down with some type of resin and had two of the square head screws in each box. My battery box shelf was rotted also and needed replacement. 1986 36 Sedan.

 

[Tawney1]

Thanks much. I agree with the Rolls in the own boxes - tempting indeed.

Since I don't intend to reuse the boxes, I am not sure we will employ much care or precaution in removing them. The box shelves in both engine rooms also have some rot, as well as the wood on the hull side where the wood meets the shelf. How tough is it to replace the box shelves and the wood on the hull side adjacent to the side of the boxes? It looks as though it would be a tough, nasty job....

I know I will have to move a good deal of wiring and there are some through hulls there as well in both engine compartments. Ugh....

 

[SKYCHENEY]

When I pulled my boxes they were set in some wetted out roving and stuck to the plywood underneath. I had to pry them loose bringing much of the plywood with them. I then glassed underneath them and completely rebuilt the boxes with new glass on the bottoms and sides. Then repainted everything. It was a big job.

 

[saltshaker]

Thanks much. I agree with the Rolls in the own boxes - tempting indeed.

Since I don't intend to reuse the boxes, I am not sure we will employ much care or precaution in removing them. The box shelves in both engine rooms also have some rot, as well as the wood on the hull side where the wood meets the shelf. How tough is it to replace the box shelves and the wood on the hull side adjacent to the side of the boxes? It looks as though it would be a tough, nasty job....

I know I will have to move a good deal of wiring and there are some through hulls there as well in both engine compartments. Ugh....

Those battery boxes are pretty pricey. If they're in decent shape and you can remove them without destroying them, you should be able to sell them if you no longer want/need them.

 

[MikeP]

"Its time to replace our battery boxes when new batteries arrive. The old boxes are in rough shape and are original Hatteras from 1985"

I'm curious as to what would cause battery boxes to need replacing. Ours are the original boxes from 1980. They are some sort of plastic and other than a few stains/discolorations they are structurally just as they were when new. With some plastic polish they would look like they were new. I had a battery crack and there was battery acid in one of the boxes for at least several weeks but it had no effect on the plastic.

Is it mechanical damage/breakage that was caused by a PO badly moving batteries in/out or some other issue?

 

[Tawney1]

"Its time to replace our battery boxes when new batteries arrive. The old boxes are in rough shape and are original Hatteras from 1985"

I'm curious as to what would cause battery boxes to need replacing. Ours are the original boxes from 1980. They are some sort of plastic and other than a few stains/discolorations they are structurally just as they were when new. With some plastic polish they would look like they were new. I had a battery crack and there was battery acid in one of the boxes for at least several weeks but it had no effect on the plastic.

Is it mechanical damage/breakage that was caused by a PO badly moving batteries in/out or some other issue?

Thanks. The boxes were in poor condition when we purchased the boat and we have managed with them so far, but for too long. I can't imagine why or how they were so abused but they were. They were dirty, chipped and cracked and remain so, and we only have two covers - not four. With the poor condition of the plywood shelf and adjacent hull wall from some rot and deterioration theyhave outlived their service life. They probably are repairable - but we only have two covers.

I know this will be a big job. Removing the batteries and boxes will be tough, but my larger concern is the removal and repair of the shelf (floor) and the adjacent hull wall.

Can anyone recommend someone in the Wilmington, NC area who is capable of doing this kind of work and knows what they are doing? Did any of you guys take photos when you made repairs to the box shelves, etc.?

Thanks.

 

[saltshaker]

Try calling Sams and see if you can buy just the tops. I'd also call Tom Slane. He may have some parts or boxes he can make. Tom would also be able to assist with work in Wilmington. I know there's a guy there who used to do a lot of work for Tom. I'm having some glass work done here in NJ by a guy Tom uses and recommends. I'm sure he has people to work in Wilmington.

 

[GJH]

Anchors Aweigh in Hampstead has a great reputation, as does Bennett Brothers. Some people go out of their way to take their boats down there from here in the Beaufort/Morehead City area. I have no direct experience with either. Perception is Anchors Aweigh offers great value.

 

[jim rosenthal]

The original Hatteras battery containers were fiberglass, and bonded to the stringers when the boat's hull was built. They are VERY sturdy and also very hard to get out (I took one out years ago, destroying it in the process. It may be possible to get one out without taking it apart, but I wonder)

Someone mentioned recently that they had four Group 31s in an 8D box, or something like that. does anyone know whether four Group 31s will fit into a Hatteras 8D box? I currently have three Group 24s set into that box, but I'd like a slightly bigger starting bank if I could get it, without having to do any surgery on the box itself.

 

[rmatt]

I posted replacing two 8d batteries with four series 31's. Two series 31 batteries will NOT fit in an 8d battery box. I replaced the boxes, one for each 31 battery. I did get my original fiberglass boxes out with a flat bar, with no damage. I replaced the wood shelf that the batteries were mounted on. Not a big deal other than the space constraints for my body. 1986 36 Sedan.

 

[saltshaker]

I think 2 group 27 batteries will fit in the 8D boxes.

 

[jim rosenthal]

I'll measure again. I got three Gr 24s in there, each crossways. I'm always looking for a few more cranking amps, but I don't want to take the battery box out.

 

[PeterK]

Can anyone recommend someone in the Wilmington, NC area who is capable of doing this kind of work and knows what they are doing? Did any of you guys take photos when you made repairs to the box shelves, etc.?

Thanks.

Nobody mentioned Bruce Morrison. He is in Beaufort. When he was working on our boat in July, I watched him fabricate a large house bank box for a Hatt when the prefabs came in the wrong size.

IMHO, you won't find a better man to work on your vessel.

 

[GJH]

Nobody mentioned Bruce Morrison. He is in Beaufort. When he was working on our boat in July, I watched him fabricate a large house bank box for a Hatt when the prefabs came in the wrong size.

IMHO, you won't find a better man to work on your vessel.

Didn't occur to me, Bruce has done a bunch of work for me, including glassing in new muffler tubes to replace cracked ones from over tightened hose clamps. Tricky job. I guess I thought wilmington was a little distant for a job like that. I'd give out his phone number but he has to get done with a job he started for me first!

 

[LARRY VALENTINE]

Its time to replace our battery boxes when new batteries arrive. The old boxes are in rough shape and are original Hatteras from 1985. Can anyone tell me how those boxes are affixed to the wood floor (which also has some rot), and the best way to remove them? Are they 5200'd in place or screwed to the floor, etc.? Anyone have experience removing the old ones?

Thanks,

Paul

First, get rid of the old LaMarche charger. It cooks the batteries and the fumes destroy the boxes. New boxes are extremely expensive. Have someone make some for you or clean up the old ones and refiberglass them. Larry Valentine

 

[nautibake]

Removed the battery boxes yesterday to make way for new AGMs and found bottoms had cracked and leaked acid on deck below. Lots of rot, ugly.

Here is what was left of the deck under the stbd bank. I'm glad that one of those Deka's didn't try to fall through.



Here is the cleaned up space where the bank was sitting. Fabricating new deck to glass in. Suspect may have the same issue on the port side.



We had looked at a Hatt last year that had a substantial amount of rot in the Generator Room, so we passed, and were extra careful to look for signs of rot in this boat, but there was no indication until the battery boxes were cut out.