DIY 12V tar top battery Optima

1941 - 1945, MB, GPW modifications, sugestions, and ideas, official MWO's and unofficial WWII field mods NO EBAY or COMMERCIAL SALES.
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bryanbdp
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DIY 12V tar top battery Optima

Post by bryanbdp » Thu Dec 03, 2020 3:15 pm

I know another 503 member is making excellent reproduction cases for the 6v optimas.
I wanted to dress up my 12V battery to make it look better. Fist I painted it matte black using fusion paint.
I purchased a sheet of 1/8" ABS plastic on Amazon https://www.amazon.com/gp/product/B000K ... UTF8&psc=1
I cut it into four pieces, two long and two short for the sides and ends of the battery.
I used plumbing ABS glue and electrical tape to glue the corners. I did one corner at a time.
When the glue was dry, I used window & door foam to fill up the spaces between the battery and the cover. This secures the cover to the battery, and stiffens up everything.
I next put a bead of urethane seam sealer around the top edges to secure the edges to the battery.
So far, so good. The textured plastic looks pretty decent.
My next step is the create the lead bridges, vents and fill caps.
Can anyone advise me on the width and length of the lead bridges?
Does anyone have a CAD file they can share for the filler caps and/or vents?
I'm not interested in selling these things, just wanted to do something about the ugly red Optima 34 battery under the hood!
I plan to 3D print the lead bridges to make a master, then cast them using plaster of paris and lead.
I'm thinking about making some perimeter hollow boxes to replicate the cell dividers and using urethane to replicate the tar.
I'll post my progress as I move forward.
20201129_193342_resized.jpg
gluing case corners
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case foamed in place
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urethane at top edges


bryanbdp
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Re: DIY 12V tar top battery Optima

Post by bryanbdp » Sun Dec 06, 2020 7:33 pm

Trying to decide what to use to simulate the tar top. I've been looking at liquid electrical tape, plasti-dip, flex seal, and a few other materials.
As I understand it, the original tar was a glossy surface?
Anyone have a good product to simulate the tar?
Thanks,
Bryan

GUNNUT in Iowa
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Re: DIY 12V tar top battery Optima

Post by GUNNUT in Iowa » Mon Dec 07, 2020 4:28 am

This should be fun. I will follow along, if you don't mind.

I have no suggestions right now . . . so I will just be standing out of the way over here in the corner.
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W. Winget
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Re: DIY 12V tar top battery Optima

Post by W. Winget » Mon Dec 07, 2020 8:28 am

I'd think to start cheap and go with flex seal. Perhaps spraying your battery down with some PAM (cooking spray) would keep the goo from fully attaching to it allowing replacement or ? maintenance.
Just a thought.
V/R W Winget

PS: When I went to seal a water fountain, along with Flex Seal there were Rustoleum liquid rubber like sealants on the same shelf in the hardware store. much cheaper than flex seal, but they were clear, some roofing products come in black though and are cheaper than flex seal I'm sure. WAW
Looking for 1918 Standard B 'Liberty' truck parts

bryanbdp
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Re: DIY 12V tar top battery Optima

Post by bryanbdp » Mon Dec 07, 2020 10:23 am

This battery will never be show quality but already looks way better than a regular Optima. The tar is supposed to be shiny, right?
I also used the 1" bottom spacer, which brings the height closer to original and allows me to notch the bottom to fit the original tray stop.
Just to be clear, if I was using a 6v battery I'd just order the other case being made!

bryanbdp
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Re: DIY 12V tar top battery Optima

Post by bryanbdp » Sat Dec 19, 2020 11:43 am

mockup in solidworks
Screenshot_1.png

bryanbdp
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Re: DIY 12V tar top battery Optima

Post by bryanbdp » Sat Dec 19, 2020 5:51 pm

final version of top
Screenshot_2.png

bryanbdp
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Re: DIY 12V tar top battery Optima

Post by bryanbdp » Sat Dec 19, 2020 5:56 pm

the two vents actually work, sort of. The optima has two vents that open under extreme pressure, and there is a relief on the bottom of the cell top piece that vents any gases out the vent opening... The center vent doesn't connect to anything.
Screenshot_3.png

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Re: DIY 12V tar top battery Optima

Post by autonoob » Mon Dec 28, 2020 6:13 pm

It seems like you are having fun with this project. I am hoping that it will work so that your effort will pay off.

bryanbdp
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Re: DIY 12V tar top battery Optima

Post by bryanbdp » Thu Jan 07, 2021 8:11 am

20210107_101009.jpg
3d printed cell covers sprayed with Rustoleum rubber coating. Looks pretty good to me.

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Re: DIY 12V tar top battery Optima

Post by iVelociraptor » Tue Jan 12, 2021 11:52 am

Would you be willing to share your STL file for printing them?

bryanbdp
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Re: DIY 12V tar top battery Optima

Post by bryanbdp » Tue Jan 12, 2021 12:01 pm

Sure!
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20210112_135907.jpg
20210112_140021.jpg

bryanbdp
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Re: DIY 12V tar top battery Optima

Post by bryanbdp » Wed Jan 13, 2021 7:31 am

Here's a drop box link of the files for the 3 cell tops, fill caps, logo medallion, and lead straps.
I sent the fill caps out to be made due to the very small text.
I created these from photos, so if anyone has better measurements, I can update the cad files.

https://www.dropbox.com/sh/gubj2xzmdb4v ... t2Wfa?dl=0


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