<html><head><meta http-equiv="Content-Type" content="text/html charset=windows-1252"></head><body style="word-wrap: break-word; -webkit-nbsp-mode: space; -webkit-line-break: after-white-space;" class="">I have always been dismayed with wooden battery boxes used in professionally installed power systems. It seems vey DIYer/HomePoweresque. Where else is wood used in electrical installations? I have on occasion built some BB plywood core boxes, sheetmetal outer skin/ FRP inner skin/ raw edges and corners banded with SS angle/ rubber gaskets with lots of latches.<div class=""><br class=""></div><div class="">I build boxes that are made of either plastic or metal depending on the environment and usage they’ll see. Plastic, that is HDPE or acrylics, I order online cut to size, or from a glass shop. 1/4” thickness. Metal, heavy gauge sheetmetal, I have cut by fabricators, and then coated with non-corrosive/conductive coatings by a cabinet shop.</div><div class=""><br class=""></div><div class="">Here are some general guidelines</div><div class=""><br class=""></div><div class="">-With either material, I keep the panels sized small. Less than 2’ x 2’ is nice, both for shipping and handling. </div><div class=""><br class=""></div><div class="">-Panels can be attached to each other using H and U channel, and angle stock (which also gives rigidity). Lids are usually sectional rather than a heavy </div><div class=""> single lid. Sometimes, on plastic lids I rout rabbets on the connecting seams so that the there is a half lap joint.</div><div class=""><br class=""></div><div class="">-Plastic can be drilled and tapped. I generally avoid using adhesives because they are toxic as Hell and pieces want to slide out of alignment.</div><div class=""><br class=""></div><div class="">-When batteries sit on metal racks, I enclose the racks with acrylic sheets using rare earth magnets. Magnets are attached to the acrylic with epoxy or the </div><div class=""> magnet will have a counter sunk hole and machine screws can be used.</div><div class=""><br class=""></div><div class="">-I seldom build a box with a back wall. Instead, I apply a sheet of FRP (fiberglass reinforced plastic) to the wall that the box sits against, smooth side out.</div><div class=""> Side panels butt against, and are attached to the wall using U channel or angle stock. This accommodates a wall that may not be flat or a </div><div class=""> wall/floor intersection that isn’t square. Corners, That is sides to front pieces are made with angle stock. They knock apart by using wing nuts or </div><div class=""> magnets. That way the front of the box can be removed for placement/replacement.</div><div class=""><br class=""></div><div class="">-I stopped using hinges for lids along time ago, when I started making lids that were sectional. Lately I run a length of U channel against the back wall, the </div><div class=""> length of the box. The width of the channel is wider than the thickness of the sheet, so that the sheet will slide in easily. The lid section is removed rather </div><div class=""> hinged up. You know the saying “Don’t let the lid hit you in the head!"</div><div class=""> </div><div class=""> -Over the years I have tried a lot of coatings in my metal boxes. All have held up well, but I have found that engine compartment type undercoatings to be</div><div class=""> my favorite.</div><div class=""><br class=""></div><div class="">-If I have a say in the power room/shed design, I will specify a concrete slab with a shallow basin for the batteries to sit in. The basin has a floor drain and is epoxy coated. Otherwise I have a sheetmetal tray fabricated and have it coated. The tray is separate from the enclosure.</div><div class=""><br class=""></div><div class=""><br class=""></div><div class="">-In very hard use applications I have the box made by a company that outfits utility and work trucks with beds and boxes. These are just large custom</div><div class=""> “truck boxes” </div><div class=""><br class=""></div><div class="">-With smaller banks, I have successfully retrofitted both gang boxes and truck/utility boxes. The simplest setup being adding some cross members to a </div><div class=""> $300.00 gang box so that the batteries sat elevated within. That makes a very nice servicing height! Again interiors are coated.</div><div class=""><br class=""></div><div class="">Growing up, I had a lot of exposure to both industrial off-grid power systems (mining, oil/gas, research, telecomm) and Maritime systems and thats</div><div class="">where my sensibilities originated. Lately I have found myself the sole off-grid specialist in a fairly vast area, and so what Im doing mostly is replacing battery banks. Lots of battery banks, and lots of rotten, corroded, nasty toxic boxes! A few weeks ago my helper and I donned Tyvex suits, rubber gloves,</div><div class="">goggles, and respirators to Demo a box that was in a dilapidated and soon to be be razed structure. The general contractor and client stood by laughing and commented that it looked like a scene from Breaking Bad!</div><div class=""><br class=""></div><div class=""><div class=""><br class=""><div><blockquote type="cite" class=""><div class="">On Jan 28, 2016, at 9:18 PM, Ray Walters <<a href="mailto:ray@solarray.com" class="">ray@solarray.com</a>> wrote:</div><br class="Apple-interchange-newline"><div class=""><span style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255); float: none; display: inline !important;" class="">Thanks for all the replies so far. I've tried foundation waterproofing membrane for a couple of years, but found it will deteriorate in high acid concentrations. IT gets all gooey and begins to dissolve. It had peel N stick adhesive, and seemed like a good idea, until later. (it was HDPE?)<span class="Apple-converted-space"> </span></span><br style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class=""><span style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255); float: none; display: inline !important;" class="">I've seen construction 10 mil plastic sheeting hold a gal of acid for many months, so I know that at least works for acid.</span><br style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class=""><br style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class=""><span style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255); float: none; display: inline !important;" class="">The pond liner looks good as well as Roy's wall plastic, but the 1/8" polypropylene would seem to be possibly more durable for about the same $$. Plastic welding looks relatively easy with a heat gun and special tip on a soldering iron, too. I'll report back on what we actually do.</span><br style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class=""><br style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class=""><span style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255); float: none; display: inline !important;" class="">As always thanks for the input, and I welcome all further comments. I feel battery enclosures are a somewhat neglected part of off grid design.<span class="Apple-converted-space"> </span></span><br style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class=""><pre class="moz-signature" cols="72" style="font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);">R.Ray Walters
CTO, Solarray, Inc
Nabcep Certified PV Installer,
Licensed Master Electrician
Solar Design Engineer
303 505-8760</pre><div class="moz-cite-prefix" style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);">On 1/28/2016 7:06 PM, frenergy wrote:<br class=""></div><blockquote cite="mid:56AAC93C.7030003@psln.com" type="cite" style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class=""><div class="moz-cite-prefix">Add to the list...I've had good luck with Grace roofing underlayment: tough and to a degree, self-healing, sticks to itself (and anything it comes in contact with) very well making seams secure, easy to find at building supply store, sticks aggressively to battery box sides without mechanical fasteners, experience has shown it resists acid. As with other solutions, something to uniformly distribute the weight and irregular bottoms of batteries should be employed.<br class=""><br class="">Bill<br class=""><pre class="moz-signature" cols="72">Feather River Solar Electric
Bill Battagin, Owner
4291 Nelson St.
Taylorsville, CA 95983
530.284.7849
<a moz-do-not-send="true" class="moz-txt-link-abbreviated" href="http://www.frenergy.net/" style="color: blue;">www.frenergy.net</a></pre><br class=""><br class="">On 1/28/2016 5:35 PM, Allan Sindelar wrote:<br class=""></div><blockquote cite="mid:56AAC1DD.9010601@sindelarsolar.com" type="cite" class="">Ray,<br class="">Just a couple of weeks ago we installed a 24V HUP set in an existing installation. We had an existing plywood battery box made of Baltic Birch (the 9-ply 12mm thick plywood typically used for cabinet drawer carcases) with a liner made of 40(?)-mil pond liner material. We removed the six cells from the steel case, set the case in place in the plywood box and lowered the cells into it. However, the box had a non-removable 5" wide strip across the top rear, and we needed to slide the entire 1100 pound case back about 8" in order to fit both steel cases.<br class=""><br class="">Before setting the steel case in the box I sprayed the floor of the pond liner with a layer of the new spray pulling lube from Klein Tools, then set the steel case in place and lowered the cells. Using a Porta-Power and some blocking, we slid the case into place with little effort.<span class="Apple-converted-space"> </span><br class=""><br class="">You might find that vinyl pond liner works well in a plywood box. We found it at a Home Depot.<br class="">Allan<br class=""><br class=""><div class="moz-signature"><div class="WordSection1" style="page: WordSection1;"><div style="margin: 0in 0in 0.0001pt; font-size: 12pt; font-family: 'Times New Roman', serif;" class=""><b class="">Allan Sindelar</b><br class=""><span style="font-size: 10pt;" class=""><a moz-do-not-send="true" class="moz-txt-link-abbreviated" href="mailto:allan@sindelarsolar.com" style="color: blue;">allan@sindelarsolar.com</a></span><br class=""><span style="font-size: 10pt;" class="">NABCEP Certified PV Installation Professional<br class="">NABCEP Certified Technical Sales Professional<br class="">New Mexico EE98J Journeyman Electrician<br class="">Founder (Retired),<span class="Apple-converted-space"> </span><span class="">Positive Energy, Inc.</span><br class=""><b class="">505 780-2738 cell</b><br class=""><br class=""><b class=""><o:p class=""></o:p></b></span></div><div style="margin: 0in 0in 0.0001pt; font-size: 12pt; font-family: 'Times New Roman', serif;" class=""><o:p class=""> </o:p></div></div></div><div class="moz-cite-prefix">On 1/28/2016 3:25 PM, Ray Walters wrote:<br class=""></div><blockquote cite="mid:56AA9568.2040506@solarray.com" type="cite" class="">Hi All;<span class="Apple-converted-space"> </span><br class=""><br class="">We're looking to improve our battery box construction, and are considering using 1/8" think polypropylene sheeting. I've used small premade boxes before, but this will be for a HUP install, and we would want to build the box around the batteries after. Does anyone have experience/ comments on welding plastic? The alternative would be to just seal the seams with acid resistant caulking. (silicone, Geocell, ?)<span class="Apple-converted-space"> </span><br class="">I've had good luck in the past just using 10 mil plastic sheeting stapled up on the inside of a plywood box, but we will be scooting 1000 lb batteries around on it, so I don't think the sheeting will hold up.<span class="Apple-converted-space"> </span><br class=""><br class="">Thanks,<span class="Apple-converted-space"> </span><br class=""><br class=""></blockquote><br class=""><br class=""><fieldset class="mimeAttachmentHeader"></fieldset><br class=""><pre wrap="" class="">_______________________________________________
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</pre></blockquote><br style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class=""><span style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255); float: none; display: inline !important;" class="">_______________________________________________</span><br style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; 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background-color: rgb(255, 255, 255); float: none; display: inline !important;" class="">List rules & etiquette:</span><br style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class=""><a href="http://www.re-wrenches.org/etiquette.htm" style="color: blue; font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class="">www.re-wrenches.org/etiquette.htm</a><br style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class=""><br style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class=""><span style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255); float: none; display: inline !important;" class="">Check out or update participant bios:</span><br style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class=""><a href="http://www.members.re-wrenches.org/" style="color: blue; font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class="">www.members.re-wrenches.org</a><br style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class=""><br style="font-family: Helvetica; font-size: 18px; font-style: normal; font-variant: normal; font-weight: normal; letter-spacing: normal; line-height: normal; orphans: auto; text-align: start; text-indent: 0px; text-transform: none; white-space: normal; widows: auto; word-spacing: 0px; -webkit-text-stroke-width: 0px; background-color: rgb(255, 255, 255);" class=""></div></blockquote></div><br class=""></div></div></body></html>