Battery Box Removal February 21, 2025, 05:35:07 pm I'm starting the planning/design process for a major electrical upgrade on the ol' 2002 26.5 MB. Plans are to have 400-600AH of lithiums and all Victron components. I already have the vast majority of necessary components, having removed them from a cargo van I just sold.Regarding the batteries specifically - the batteries I'm repurposing (200AH Lifeblues) will neither fit in the external battery box or under the fridge. They will however, fit beautifully if I open up that entire area by removing the battery box.The exterior battery door will be nice for access, but with the battery box gone I'd like to seal it up better from the elements. The Lifeblues are heated, but for both protection of the batteries and interior heating efficiency of the coach I'd like to remove this significant thermal transfer point best as I can.Has anyone undertaken a modification like this? Yes or no - and words of wisdom before I start in on it?
Re: Battery Box Removal Reply #1 – February 21, 2025, 05:48:59 pm No, kept the battery box, but yes, I have modified it for thermal protection. I have a 1" thick foamboard precision cut to press-fit the opening behind the door, with moisture-blocking rubber insulation on its perimeter. Then I plugged the door ventilation holes with more foam. finally, I cut holes and installed ventilation ducts from the battery box to the coach interior.Steve 2 Likes
Re: Battery Box Removal Reply #2 – February 22, 2025, 04:50:51 pm Steve's solution sounds first class. I went with the keep-it-simple method and just covered the vented exterior door with reflectix and foil tape. I didn't bother with any ventilation. Just use the old drawer face and door for access.jor
Re: Battery Box Removal Reply #3 – February 22, 2025, 07:15:38 pm Lots of documentation, measuring and wire tracing today. However, on the topic of the battery box/battery tray - I did get the battery tray out.I thought I read somewhere on here it was a nasty job, but with the right tools it came out in minutes. For those who just want an empty, bare battery box it's a piece of cake. The Reader's Digest version:- Bend both rear tabs on sliding tray inward, slide the tray out.- You'll be left with two brackets on each side. Use a multitool to cut away at the sealant (Dicor?) on top of both brackets. Peel it away, exposing two lag bolts per bracket. Remove the lags.- Use the multitool to cut the sealant along the inside edge of the brackets at the base of the battery box.- Slide a flat, wide prybar in the new gap between the bottom of the battery box and the sealant you just cut. The brackets will pop right off, along with the 1/4" ply strips they sit on top of. 2 Likes
Re: Battery Box Removal Reply #4 – February 23, 2025, 01:15:28 pm If you are willing to move the circuit breakers in the battery box, the box can be cut away. An airtight box is not needed with lithium batteries The box is there because the Factory lead-acid batteries off-gas highly explosive hydrogen gasUse your vibratory tool to cut the box away.Like Steve, the outer LD's battery compartment door is sealed and a tight-fitting 1" foam block is placed behind the door.I added vents to the interior, along with a remote temperature probe to monitor the battery compartment temps. The batteries stay within a few degrees of the interior temps, in summer, and winter.Lithium battery upgrade | FlickrLarry
Re: Battery Box Removal Reply #5 – February 26, 2025, 03:42:03 pm Thanks, Larry. Yes, everything was gutted from the old battery box as new fusing/circuit breakers will be part of the planned Victron installation.The battery box is out. Unlike the sliding tray, which took minutes - removing the battery box itself took the better part of a day. No expletives were spared in the process...it is not for the faint of heart. A multi-tool helps, but the worst part is the massive amount of Dicor removal required which requires a bit of precision. It covers around a dozen screws around the edge of the box, all of which must be removed. Worse - it coats the bundles of wire entering the box. Lots of patience, careful cutting of Dicor with the utility blade, and even then I nicked a couple wires that will require repair. And, since there's no easy way to remove the battery box as a single unit - the multitool took it out in chunks. However, that was time consuming and nerve wracking as there are so many things to avoid when cutting through the sides of it. Water tank, propane line, more wiring bundles...again, plenty of opportunity to make mistakes.What I will say is, the difficulty in removing the battery box gave me a new appreciation for LD build quality. They aren't the easiest rigs to upgrade, but...most everything put in from the factory is designed to never need attention again.
Re: Battery Box Removal Reply #6 – February 26, 2025, 05:19:05 pm Quote Unlike the sliding tray, which took minutes - removing the battery box itself took the better part of a day. That sure reflects my experience! I also nicked a couple of wires. As for the factory's installation with the massive application of Dicor, totally unnecessary and poorly done. jor
Re: Battery Box Removal Reply #7 – February 26, 2025, 05:41:05 pm Fortunately, I only nicked one wire and didn't damage the conductor - just the insulation. And, it was a ground cable - so some electrical tape and/or shrink tube will fix it up fine. 1 Likes
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