17 October 2014

New Battery for the DeLorean

I was having trouble starting the car, this happened twice in the last few months.  I did some testing with a volt meter and it was obviously the battery as it was not holding a charge.  Better to be the battery and not the alternator.  At least with the battery I can swap out with relative ease.

Missing the 'loop' part of the latch
I am going with a smaller, lighter battery that still packs a punch.  Before I install the new battery, I need to make sure smaller battery will be secure in the battery compartment.  There is a strap to keep the battery from moving, but I am missing half of the latch/hook system.

Sketches of the new latch
So, I will have to make one.  First, some sketches, a simple design.  I have no idea what the original one looks like, and I was unable to find images of one on the internet.  I did not look very hard.  This should be simple enough.  I took some measurements off the existing 'hook' and used that as my guide.

Laying out the lines in Illustrator
Next step it so to layout the lines in Illustrator in preparation for the laser cutter.  I need something a little stronger than styrene, so we are going with Delrin, again.

Delrin battery strap latch
The slot on top is for the hook, while the two slots on the bottom allow the strap to be adjustable.  The advantage of having access to a laser cutter, other fun tools, and co-workers willing to help out.  Meanwhile, I ordered a replacement battery and it should be here in a few days. 

Odyssey PC925L Battery
Here is my little battery.  So cute.  I did  a quick volt check and installed it in the car.  The old battery is about 40 pounds, while the new battery weighs in at 24 pounds. 

Strap is too long
Since the battery is smaller, the strap is too long.  Looks like I will have to come up with a strap shortening device.

Battery strap shortening thing
There are many similar/better strap or seat belt shortening clips out there. Of course, I realize this after I had my clip made.  Most of these seat belt clips only shorten the belt about three inches, I needed my strap about eight inches shorter.  Although, I could have borrowed and modified the design to shorten the strap to the appropriate length.

Delrin strap shortening clip and strap latch
Clip and strap works, batter is locked down.  Oh, and the new battery works, too.  I should be able to get a few years from this battery.  One less thing I have to worry about...until the next thing goes wrong with the car.

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