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Old 07-29-2022, 11:20 AM   #1
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Need steel thickness advice: battery base

I need to mount our house batteries on a metal plate, which will be supported only on 2 opposing edges (its 3" over the access panel for our tranny, so no support from underneath.). The batteries will pretty much cover the entire panel with the exception of the 2 mounting edges. The size of the panel will be the footprint of the batteries, which is 14.5" x 24", plus 2" on the two ends where it will mount, so 19.5" x 24" total. The batteries total 170lbs. Obviously I need this strong enough to not flex at all, and to secure the batteries in the event of a collision.

I'm thinking 1/4" steel, but honestly, this is just a gut-feel analysis. It anyone thinks I'm off here let me know. I don't want it to weigh any more than it has to, but I'd rather err on the side of strength.

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Old 07-29-2022, 12:48 PM   #2
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Im extending my front bumper 12in to mount a winch and another 8d (150lb) battery. Im building the top and bottom of the bumper plate out of 1/8 treadplate. 1/8 treadplate is used on heavy trailers and flatbed stake trucks.



My current battery tray that holds 2 8d batteries on a slide out tray is only built out of 1/8 with the sides bent up 1in.


I'm all for overbuilding, but with the price of steel and if i double the weight of all the steel i'm putting on, it will really add up on my bus.


Personally, if it were mine, i would weld angle iron to the perimeter of 1/8 to strengthen the flex and give the hold down clamps something to lock into.
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Old 07-29-2022, 01:02 PM   #3
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i made mine from 2"angle iron.

with the batteries, i was around 300 pounds. the rack and the batteries were sitting in the bus factory storage compartment so i could slide it in and out. it was only supported by the bus sheet metal and smaller angle than i used on the battery rack.

now with the lifepo battery, that box stores hoses and electric cords.
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Old 07-29-2022, 01:40 PM   #4
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well....

I think 1/4" is way over kill.... 0.100" or 2.5mm sheet is enough.. If you dont have access to a sheet metal brake to bend up the edges, then weld an edge around it... instead of bending a lip on all four sides you are going to weld a piece to all four sides... If flex is worrisome to you... then weld a rib underneath... kind of like a mini I beam.

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Old 07-29-2022, 03:13 PM   #5
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Semi-retired welder-fabricator here.
.
If I was me, I would start with a bigger piece of steel than the finished dimensions.
I would bend both long sides to form a flat 'C'.
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I could also weld a stiffener down the center of the length.
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Either route adds significant rigidity.
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Alternatively, I might consider mounting the weights over the frame rails instead of between the rails.
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Old 07-29-2022, 03:30 PM   #6
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Just to add one more data point, my stock battery bay has two trays, each that holds a big 8D battery. The trays are empty rectangles of 1/8" x 1-1/2 angle iron (i.e. battery is only supported along the outside edges). Each tray is supported along one short side and one opposing corner. It's a difficult setup to explain with words only, but the point is that it looks minimal at best, flimsy at worst, but seems to have held up well for many years.
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Old 07-30-2022, 09:47 AM   #7
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Thanks everyone. This has helped tremendously. Saved me $ & #s. Don't have the ability to cleanly bend the sheet but I can weld the edges & bottom support.
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Old 08-10-2022, 10:49 PM   #8
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This is a re-post of a picture of the battery trays in my "new Crown". Tejon 7 described them, and here is a picture. The front end is mounted with a verticle tube or rod, that the trays pivot on and the rear has a ledge that supports the rear and has through bolts to hold battery trays still.
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