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  1. #1
    bowsniper's Avatar
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    A better battery cover

    I was always having trouble keeping that cheezy cover on top of the battery to prevent a short. I made this one up as a new prototype out of cardboard and tape before I make it out of fiberglass. I opened the ends up more so you can hook up the cables from different directions a little easier and the side are lower so it doesn't slip off.

    Whatcha think?
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  2. #2
    Click avatar for tech links/info, donation request K447's Avatar
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    Fiberglass

    How about something that has a little flex and give? Perhaps a polypropylene type material that you could heat weld...

  3. #3
    Hayabusa's Avatar
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    bow, great idea but I'm not sure your design as is, is going to work. From what I can see, if you connect the battery cables up first, you might not be able to slip the cover on. If you wait until the cover is on before installing the cables, you wont be able to get in there to make the connections.

  4. #4
    ryandi2's Avatar
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    bow i like the idea..but i would put openings on top.. this would make it easyer to connect too the battery posts

    see red arrows below..
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  5. #5
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by bowsniper View Post
    I was always having trouble keeping that cheesy cover on top of the battery...
    Isn't there a strap to hold it all in place?

  6. #6
    bowsniper's Avatar
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    Ok. ill put it back on the ski and see how it hooks up. well keith, when I'm on the ski in the lake and have to mess with the battery...that cover is just a real pain in the **& . ya go to strap it on and it slides to one side and slips easy. if the cables arent put on exactly like the oem diagram.. they dont hook up easy...
    I didnt make any cut on top because you dont want the top of the terminals to touch the base of the cdi cover.

    Why make it flexible? it doesnt need to be.. yeah, ill still put straps over it and it will fit in the cdi base.

    Plastic welding material? never worked with that stuff.


    Haybusa, maybe I can make the openings all the way to the bottom of the cover so it will slip on..

    Ill just have to get it on the ski and see what it takes to make this work better.. still just an idea. I can change anything on it. had to start with something... Thanks for the ideas and insight..

  7. #7
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by bowsniper View Post
    ...when I'm on the ski in the lake and have to mess with the battery...
    I would certainly hope that would be the rare case.

    When you are out on the water, the electrical system should just work - no issues, at all.

    The Deka ETX16LM AGM batteries that I currently use (also sold by West Marine) have two sets of bolt holes in the posts. One hole on the top of each post, another on the side of the post. It gives you some cable mounting options.

    I don't like the fiddly brass spacer washer that Deka supplies, but then again I have never needed to disconnect a battery cable while anywhere but on the trailer or shop cart.

    Also sold by West Marine, these come with a plastic spacer pad, which I cut and re-purposed as a spacer cap, under the OEM Polaris battery cover.
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  8. #8
    ryandi2's Avatar
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    Quote Originally Posted by bowsniper View Post
    Ok. ill put it back on the ski and see how it hooks up. well keith, when I'm on the ski in the lake and have to mess with the battery...that cover is just a real pain in the **& . ya go to strap it on and it slides to one side and slips easy. if the cables arent put on exactly like the oem diagram.. they dont hook up easy...
    I didnt make any cut on top because you dont want the top of the terminals to touch the base of the cdi cover.

    Why make it flexible? it doesnt need to be.. yeah, ill still put straps over it and it will fit in the cdi base.

    Plastic welding material? never worked with that stuff.


    Haybusa, maybe I can make the openings all the way to the bottom of the cover so it will slip on..

    Ill just have to get it on the ski and see what it takes to make this work better.. still just an idea. I can change anything on it. had to start with something... Thanks for the ideas and insight..

    but the fber glass will cover enough that you wont have too worry about it at all. at least thats what i would think..

  9. #9
    I'D RATHER SWEAT THAN SHIVER hyoctane23's Avatar
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    I honestly question the need for a battery cover to begin with. Is this going to be for your Pro 785 or your other ski?

  10. #10
    ryandi2's Avatar
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    Quote Originally Posted by hyoctane23 View Post
    I honestly question the need for a battery cover to begin with. Is this going to be for your Pro 785 or your other ski?
    on the skis that the e-box sits on the battery top its self yes you need it... my sl1050 computer fried because the cover fell out of place and fried it up

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