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Old 08-17-2012, 01:50 PM
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Default Battery Hold-Down Converted from Bolt to Stud

When I purchased my car, I needed to thoroughly clean the cooling system. When I first attempted to remove the coolant overflow reservoir I broke the battery hold-down bolt because it was rusted to the mounting tray on the body. It was brilliant for the designer to put a side-post battery on top of the coolant reservoir in order to concentrate the two most caustic chemicals in the vehicle.



My solution was to convert from a bolt threaded into the body to a stud to avoid this in the future. I'm sure there are other/better ways but this is what worked for me.

After a year it seems to be holding together fine so I thought I would share. I only took a few pictures so included what I could.

Materials:
5/16"-18 x 3.5" Bolt fully threaded if possible (Stainless Steel)
Note: I used a 2.5" and had to cut the tie-down block in half because I did not properly mock it up.
5/16" Washer (Stainless Steel)
5/16"-18 Nut (Stainless Steel)
JB Weld

Tools:
Dremel or other tool with cutoff wheel
Wire brush if area is rusty (highly likely if you ran into this issue)
Drill
5/16" bit (may also need 3/8")


1. Cut off any remaining section of the bolt as close to the surface of the mounting tray if necessary.



2. Drill out original bolt and thread from original caged nut if necessary. (No photo available)

3. Clean area with wire brush. (No photo available)

4. Test fit by taping the bolt from underneath and setting then carefully dropping the coolant reservoir, battery, hold-down block and washer into place.



5. You may be able to carefully thread the nut on, but it should only be necessary to place it next to the threads to ensure there is sufficient thread extending above the top of the tie-down block, but not so much that you cannot use a deep-well 1/2" socket.

I think a 3.5" bolt will be the right length. I did not mock mine up properly and the 2.5" bolt required I cut the tie-down block in half.

6. If everything fits properly and the bolt head sits flush from underneath proceed to JB Weld it in place. (Follow the mixing and application instructions on the package).

7. I applied the JB Weld fairly liberally to the bolt head and underside of the mounting tray. I did not apply to the top in order to avoid a raised area that could cause alignment issues.

8. You may be able to drop everything into place and clamp it down, but I think I ended up just putting down the washer and hand-tightening the nut to hold the bolt in position while the JB Weld cured.

9. Place the reservoir, battery, tie-down block and washer in place over the stud.

10. Carefully thread the nut onto the stud and be sure not to over tighten, it just needs to hold the battery firmly in place. JB Weld has a fairly high sheer strength so I doubt this application will test it.

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Last edited by AUscorp1; 08-17-2012 at 01:51 PM.
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Old 08-17-2012, 02:10 PM
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very nice. I'll move this to the how to section. good job.
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Old 08-17-2012, 02:12 PM
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Now back to the good part.
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I know someone who needs to do this.
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Old 08-17-2012, 03:18 PM
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Thanks for the feedback guys.
I've wanted to post this write-up for a while so hopefully it helps someone out down the line.
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Old 08-17-2012, 09:58 PM
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sticking this. i had this problem when i had my camaro. the battery was held in by a wood block
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Old 08-17-2012, 10:21 PM
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Wood block, I'd like to see a pic of that!
Did you screw it to the plastic tray?
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