04-18-2009, 06:17 PM #1
The Fullboogie Custom Battery Box!
It's been raining all day and I was bored, so I decided to start my battery box/CDI box relocation project. This was not easy and it took a loooong time, but the results are worth it. Check it out:
Here's what I started with:
After lots of careful measuring and marking, I used a jig saw to cut it out:
You have to crimp the rear upper strap hold-down to make it a "permanent" one, and then install another an "open" one on the front side. Here's what it looks like on the bench with the battery installed:
Drill holes on the back of the battery bucket with a 3/16" bit, and drill another one as indicated in the picture below. Fit it in place and mark the hull for drilling. Use 3/16" aluminum rivets and test fit everything. Put an assload of 5200 on the back side and on the "pedestal" on the right, and fit it in place. Pop the rivets in and this is what it looks like:
And here's what the finished product looks like. It's in there ROCK SOLID and the 5200 isn't even dried yet. You like????
04-18-2009, 06:26 PM #2
Holy Cow !!! AWESOME !!!!!!!! Now that right there is CLEVER !!!!
04-18-2009, 06:26 PM #3
nice job!!! i was wanting to do this myself....can you post a pic of the finish cdi?
04-18-2009, 06:29 PM #4
04-18-2009, 06:37 PM #5
- Join Date
- Oct 2005
fckn hey that`s is kick arse right there bro!
04-18-2009, 07:37 PM #6
Here are the aluminum rivets you will need. You can get them from Home Depot:
04-18-2009, 07:39 PM #7
- Join Date
- Oct 2006
very clean setup
04-18-2009, 08:55 PM #8
Thanks guys - it was a lot of hard work. If I had the pics above and knew what rivets to get ahead of time, it would have been much easier. Most of the time was spent shaping and fitting and going to the store. I hope these pics make it easier to duplicate - just send me a $20 royalty for using the Booger Box and I'll be happy.
Tomorrow I'll work on the CDI box and post up pics. That's going to be one hell of a project too...
04-18-2009, 08:55 PM #9
04-18-2009, 09:36 PM #10
were you able to salvage the top rim of the battery box where the seat seals to it?
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