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2012-2013 Boss 302 Mustang
Out of the ashes, a Phoenix is born (Boss 302 teardown and rebuild)
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<blockquote data-quote="ford20" data-source="post: 15251767" data-attributes="member: 140884"><p>Since my car has been sitting for so long I definitely needed a new battery and I wanted to go ahead and go with something a little bit lighter than stock. JPC Racing built this really cool looking and functional battery tray and breather combo right here and used a Braille B2015 battery.</p><p></p><p><img src="http://cdn2.bigcommerce.com/server4600/4a25f/products/51853/images/29277/DSCF6691__98591.1459190382.1280.1280.JPG?c=2" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Considering I already have my Peterson Breather Can, I couldn’t justify spending all of the money on the new setup right away. I might go ahead and grab it in the future, but as of now I couldn’t do it. So I went out and bought the same Braille B2015 battery which should be perfect for what I will use it for. It is very small and compact and only weighs 15 lbs. which will save me about 16lbs. off the front end and have enough CCA to get the car up and running without issue. The problem is that the battery is MUCH smaller than the factory battery so I would have to fabricate a way to keep it in place. Since weight savings is life bc racecar I decided to make it out of Carbon fiber. So I went out and bought a 12” x 24” sheet of Carbon fiber and some carbon fiber 1” angle to make and reinforce the battery box with. After taking my measurements I went ahead and fabricated the box. Here it is with the front and back all mocked up followed by the sides.</p><p></p><p><img src="https://c2.staticflickr.com/2/1700/26046175681_384c7be20d_b.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p><img src="https://c2.staticflickr.com/2/1663/26020004502_6dea858bf7_b.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>In order to cut the carbon fiber I used a hacksaw and a tungsten carbide blade as it will not cause the carbon fiber to chip or splinter as you cut it like it would with a wood cutting or metal cutting blade. You should also wear gloves and a long sleeve shirt when cutting carbon fiber as in my research, it is very much like fiberglass as the particles can get stuck in your pores and cause all sorts of itching everywhere and it is a worse sensation than fiberglass is. Also, some sort of mask would be advisable as well as safety goggles just in case. I’m still sneezing Carbon Fiber dust out of my nose 4 days later so it would be a nice thing to have thought about at the moment.</p><p></p><p>From there I cut the bottom of the carbon fiber piece to fit in the battery tray to give it a sort of finished look to it. After a lot of sanding I got it to sit nice and flat in the tray <img src="data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7" class="smilie smilie--sprite smilie--sprite8" alt=":D" title="Big Grin :D" loading="lazy" data-shortname=":D" /></p><p></p><p><img src="https://c2.staticflickr.com/2/1662/26112524955_52a19ac0ec_b.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p><img src="https://c2.staticflickr.com/2/1586/25509907643_410fca828d_b.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>I still have to cut the bottom try so that I can put the bolts in and take them out with ease as well as cut the insert for the nylon strap to go through since I am changing the way it mounts. I am thinking of mounting it to the battery tray down here with 2 rivets in the same way that the factory strap is mounted assuming I can fit a rivet gun in that space so that the rivet is mounted directly to the strap the way it is from the factory.</p><p></p><p><img src="https://c2.staticflickr.com/2/1619/25511600863_7eb12e9e95_b.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>I ended up buying <a href="http://www.mcmaster.com/#98778A525" target="_blank">these rivets from McMaster-Carr</a> and looking at the material thickness range I think I will be in good hands considering the plastic at that spot I believe is .118” judging by the plastic closest to it where I could take a measurement and the nylon strap is .074-.080” so with any luck this will work. This rivet appears to be almost the same rivet used ts the factory except that the factory one has a large washer for lack of a better term built into the back of the rivet where this one doesn’t.</p><p></p><p>Anyway, I got the box all mocked up and grabbed my 3M 110 Epoxy and started epoxying the Carbon Fiber angle onto the sheets of Carbon Fiber. I opened up the box a little bit more to allow the battery to be put in easier so there is a little bit of a gap where you can see the carbon fiber angle, but nothing too bad. Here is where I ran in to a bit of an error as per the norm with me. When I got my epoxy, they sent me a mixing nozzle for a 200ml tube which has a large round ended hole when I actually got a 50 ML tube which has a rectangular attachment that fits into a slot. So I ended up modifying it and it sort of worked. The epoxy barely made it through the tube before leaking out on me so I aborted that idea and cleaned everything off. So I went to the Home Depot and grabbed some Loctitie Epoxy which has a mixing nozzle in it that is a similar mounting design, only problem is that it was too small :/. So I finally got the correct ones from the vendor yesterday and went ahead and started epoxying all of the pieces together. Today I will go ahead and finish the supports for the bottom so that I can mount it to the bottom tray once I cut all my holes and put the strap into the battery tray etc.</p></blockquote><p></p>
[QUOTE="ford20, post: 15251767, member: 140884"] Since my car has been sitting for so long I definitely needed a new battery and I wanted to go ahead and go with something a little bit lighter than stock. JPC Racing built this really cool looking and functional battery tray and breather combo right here and used a Braille B2015 battery. [IMG] http://cdn2.bigcommerce.com/server4600/4a25f/products/51853/images/29277/DSCF6691__98591.1459190382.1280.1280.JPG?c=2[/IMG] Considering I already have my Peterson Breather Can, I couldn’t justify spending all of the money on the new setup right away. I might go ahead and grab it in the future, but as of now I couldn’t do it. So I went out and bought the same Braille B2015 battery which should be perfect for what I will use it for. It is very small and compact and only weighs 15 lbs. which will save me about 16lbs. off the front end and have enough CCA to get the car up and running without issue. The problem is that the battery is MUCH smaller than the factory battery so I would have to fabricate a way to keep it in place. Since weight savings is life bc racecar I decided to make it out of Carbon fiber. So I went out and bought a 12” x 24” sheet of Carbon fiber and some carbon fiber 1” angle to make and reinforce the battery box with. After taking my measurements I went ahead and fabricated the box. Here it is with the front and back all mocked up followed by the sides. [IMG] https://c2.staticflickr.com/2/1700/26046175681_384c7be20d_b.jpg[/IMG] [IMG] https://c2.staticflickr.com/2/1663/26020004502_6dea858bf7_b.jpg[/IMG] In order to cut the carbon fiber I used a hacksaw and a tungsten carbide blade as it will not cause the carbon fiber to chip or splinter as you cut it like it would with a wood cutting or metal cutting blade. You should also wear gloves and a long sleeve shirt when cutting carbon fiber as in my research, it is very much like fiberglass as the particles can get stuck in your pores and cause all sorts of itching everywhere and it is a worse sensation than fiberglass is. Also, some sort of mask would be advisable as well as safety goggles just in case. I’m still sneezing Carbon Fiber dust out of my nose 4 days later so it would be a nice thing to have thought about at the moment. From there I cut the bottom of the carbon fiber piece to fit in the battery tray to give it a sort of finished look to it. After a lot of sanding I got it to sit nice and flat in the tray :D [IMG] https://c2.staticflickr.com/2/1662/26112524955_52a19ac0ec_b.jpg[/IMG] [IMG] https://c2.staticflickr.com/2/1586/25509907643_410fca828d_b.jpg[/IMG] I still have to cut the bottom try so that I can put the bolts in and take them out with ease as well as cut the insert for the nylon strap to go through since I am changing the way it mounts. I am thinking of mounting it to the battery tray down here with 2 rivets in the same way that the factory strap is mounted assuming I can fit a rivet gun in that space so that the rivet is mounted directly to the strap the way it is from the factory. [IMG] https://c2.staticflickr.com/2/1619/25511600863_7eb12e9e95_b.jpg[/IMG] I ended up buying [URL="http://www.mcmaster.com/#98778A525"]these rivets from McMaster-Carr[/URL] and looking at the material thickness range I think I will be in good hands considering the plastic at that spot I believe is .118” judging by the plastic closest to it where I could take a measurement and the nylon strap is .074-.080” so with any luck this will work. This rivet appears to be almost the same rivet used ts the factory except that the factory one has a large washer for lack of a better term built into the back of the rivet where this one doesn’t. Anyway, I got the box all mocked up and grabbed my 3M 110 Epoxy and started epoxying the Carbon Fiber angle onto the sheets of Carbon Fiber. I opened up the box a little bit more to allow the battery to be put in easier so there is a little bit of a gap where you can see the carbon fiber angle, but nothing too bad. Here is where I ran in to a bit of an error as per the norm with me. When I got my epoxy, they sent me a mixing nozzle for a 200ml tube which has a large round ended hole when I actually got a 50 ML tube which has a rectangular attachment that fits into a slot. So I ended up modifying it and it sort of worked. The epoxy barely made it through the tube before leaking out on me so I aborted that idea and cleaned everything off. So I went to the Home Depot and grabbed some Loctitie Epoxy which has a mixing nozzle in it that is a similar mounting design, only problem is that it was too small :/. So I finally got the correct ones from the vendor yesterday and went ahead and started epoxying all of the pieces together. Today I will go ahead and finish the supports for the bottom so that I can mount it to the bottom tray once I cut all my holes and put the strap into the battery tray etc. [/QUOTE]
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Out of the ashes, a Phoenix is born (Boss 302 teardown and rebuild)
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