Date:         Thu, 7 Jul 2005 20:43:13 -0700
Reply-To:     Paul Guzyk <paullist@GUZYK.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Paul Guzyk <paullist@GUZYK.COM>
Subject:      Re: Optima Battery safety question
In-Reply-To:  <AIEFIGCNNANNIHLNFBPEKEEFAGAB.mailinglist@fastforward.ca>
Content-Type: text/plain; charset="us-ascii" ; format="flowed"

Here's what I did on one install:

http://www.californiavan.com/battery/Battery.html

1) Remove the upper turntable if the van has Westy seats then chop
about 1 1/2 inches away from the rear section of the lower turntable
base.  (see photo) I used a Dremel cutting wheel to remove the
section.

2) Use the Optima without side terminals, the way nothing can short
to the battery cover tin.

3) Shim the battery compartment with wood blocks to keep the battery
from moving about.

4) Cover the positive terminals with an old rubber inner tube just to
be extra safe.

5) Use a Surepower model 1315 battery separator instead of the wimpy
VW relay.  While the Surepower is a tad expensive at $70, it's the
best possible way to hook up two batteries in a Vanagon.  Intelligent
charging, automatic separation when engine is off and automatic 2nd
battery starter assist for those times when you left the park lights
on....it's also compatible with Subaru alternators and the VW
alternator idiot light without having to do any extra wiring.

-Paul Guzyk


>Tonight I installed a Group 34 Optima battery in my TriStar.  I did as many
>people have done, laid it over on it's side so the terminals point forward
>and then secure the battery clamps.  Has anyone ever started arc-welding
>using this method or have a battery be a projectile in an accident?  With
>the battery on it's side the positive clamp is only a few millimetres away
>from the floor under the seat and there is no way of securing the battery.
>What I did to make me feel half at ease, is use the stock clamp down bar to
>force the battery to the rear of the tray so it can't lift up and used four
>layers of water softening salt bag under the positing terminal so will not
>[hopefully] touch if the Syncro goes on a weird angle or gets into an
>accident... but it can still slide from side to side - if it goes too much
>to the passenger side the positive clamp will touch the factory battery
>retaining bar.  I have inserted a 2x4 and a 1x4 piece of wood on the
>passenger side of the battery to keep it in the driver side of the tray...
>someone please tell me there is a more elegant and safe way of doing this!
>
>David Marshall