Any way to make carriage bolt holes without machine shop?

[gumpy]

The problem with using plastic rather than wood is that the acid that leaks out of the batteries will run off the plastic and onto the aluminum bus bay. Plywood will absorb the acid, and keep it in place. Yes, over time, it will deteriorate, but when it does in 5-10 years, you can just cut a new piece and replace it. It works very well and keeps the acid from eating your bays.

Definetely plywood over plastic for batteries unless the plastic is in the form of a fully contained box.

[Len Silva]

There is no mechanical problem that cannot be solved with brute force and ignorance.

[kyle4501]

If it jams, force it. That is why they make bigger hammers.
If it breaks, it probably needed replacing anyways. . . .

[belfert]

The problem with using plastic rather than wood is that the acid that leaks out of the batteries will run off the plastic and onto the aluminum bus bay. Plywood will absorb the acid, and keep it in place. Yes, over time, it will deteriorate, but when it does in 5-10 years, you can just cut a new piece and replace it. It works very well and keeps the acid from eating your bays.

Definetely plywood over plastic for batteries unless the plastic is in the form of a fully contained box.

I am using AGM batteries so I have bigger problems if they ever discharge any acid.  My golf cart batteries seemed to always be coated in a layer of crap even though they never seemed to need any water when I checked them.

[gus]

Whatever you put underneath batteries should not be solid unless it can hold moisture away from the metal. Anything else will allow moisture and acid between it and the metal and provide perfect corrosion conditions.

If you have nothing that will hold water then trips of rubber or solid wood are best because they allow air circulation under the battery.

Plywood will, indeed, absorb the wet overflow and provide perfect corrosion conditions. Plywood is a perfect sponge. The whole idea is to keep the metal compartment floor dry. If it is dry it won't corrode.

My only complaint about plastic is it will let the battery slide around because it is very slick.

[Dallas]

Actually,
I didn't mention using plastic for the whole floor.
what I mentioned was cutting strips from a plastic cutting board to use instead of the angle iron that he was talking about.

[gus]

Dallas,

I knew that but didn't make myself clear. All the plastic I have found is pretty slick stuff.

I would never make a solid battery bottom cover unless it would positively hold liquids away from the metal. I've never tried to do this because the rubber strips work so well.

[belfert]

My plan is still to use the aluminum angle as I already have it.  I just need a little strip of something along the edges to go over the bolt heads to keep the bolt heads from wearing through the battery case over time.