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Fitting two batteries in 90 battery box


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I am shortly fitting a pair of batteries with split charge in the 90 but I am a little concerned because if I mount the batteries side by side I have to raise the batteries to take into account the slight dip in the bottom of the battery box. This makes the rear terminals about 5mm from the edge/lip of the battery box and not far from the battery box cover that’s metal :unsure: .

I have got heavy duty terminal covers but would feel happier if I had another 10mm clearance between the terminals and a steel lid.

Just wondering if anyone has modded/ deepened their battery box and how did they do it?

I could mount the batteries in a T configuration as that would give me about 10mm clearance but I would have to find some Heath Robinson method of fixing the batteries so they don’t move about and also so it doesn’t fail its MOT. How have you fixed yours?

Any suggestions welcome.

J2J

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welded a plate in the bottom with a tapped hole in the middle, 2 lengths of M6 studding, and a piece of bar across the top. I used nyloc nuts to make sure it didn't vibrate loose.

Mine actually doesn't get checked at MoT, its too difiicult to get at as I have a plywood distribution board bolted on top.

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I put a length of U section alloy in the depression & have my 2 big Odyessy pc1700 side by side in my 110's battery box, not much room for anything else, if the lid has the silver foil covered insulation on the inside face, cover it with insulation, 2 leyers of grey 4 inch wide duct tape on mine.

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Just considering this myself, my two Numax don't fit, so i was planning on cutting out the tapered bottom bit and re-building it with fiberglass making it square, just keeping it above the rock slide/sill panel... P48 is brilliant stuff, very strong.

Mav

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I have 2 in mine along with a small air compressor. Its a tight fit but it all works fine :)

Mike (gemini) modded the box in his 110, there were photos over on LRA but I imagine they are no longer there.

He will probably pop his head up soon.

G

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This is mine, I've offset mine to the left so there's enough room to get two isolation solenoids in at the side of them.

post-2025-0-26996900-1335773911_thumb.jpg

I use a piece of fairly rigid plastic sheeting that sits on top of the batteries for additional security, particularly when the seat box cover is being removed/replaced. It's one of the cheap universal rear mud flaps that most of the motor sport specialists sell.

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Going to see a mate of mine who is a fabricator on Saturday and see if he can make me a simple two piece drop in and rivet tray to drop in the hole I am going to cut in the bottom of the battery box :rolleyes: dropping the box by about 1"

If it works out I will post up some images.

J2J

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Just considering this myself, my two Numax don't fit, so i was planning on cutting out the tapered bottom bit and re-building it with fiberglass making it square, just keeping it above the rock slide/sill panel... P48 is brilliant stuff, very strong.

Mav

I beg to differ.

I have two Numax batteries in my 110, it's bloody tight but they do fit.

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Remember the battery box floor is stepped because the chassis is in the way for part of it. So you can only lower the floor on the part of the box that's outboard of the chassis rail.

I replaced my box with a YRM one when it rotted out, which increases the space available a bit as well.

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Here is mine: (Note this is a Devon4x4 Twin Battery Tray shown without the battery retaining strap)

Containing 2 x Exide Maxxima. 1 x Additional fuse box (protected by a 60amp HD fuse). 1 x Albright HD contactor / isolator, monitored by a genesis battery monitoring system.

IMG_1633.jpg

Mounted on the front is the winch isolation switch and an Anderson jump start plug outlet.

IMG_1645.jpg

Regards

Rob

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The way I recommend is to build up the dip in the bottom of the box with a few sheets of MDF or similar so that it's only 10-15mm deep. Then mount the two batteries opposite ways round such that the +ve terminal of each battery sits in the dip. This lowers the +ve terminals by 10-15mm and makes the two batteries form a V if you were looking from the front of the vehicle. The original retaining strap then just sits in the bottom of the V which holds the batteries very securely. The -ve terminals stick up and may well touch the underside of the seat box lid - but since it's connected to -ve anyway, that does not matter.

This gives enough space for 2 x Numax batteries which are taller than most others.

Si

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The way I recommend is to build up the dip in the bottom of the box with a few sheets of MDF or similar so that it's only 10-15mm deep. Then mount the two batteries opposite ways round such that the +ve terminal of each battery sits in the dip. This lowers the +ve terminals by 10-15mm and makes the two batteries form a V if you were looking from the front of the vehicle. The original retaining strap then just sits in the bottom of the V which holds the batteries very securely. The -ve terminals stick up and may well touch the underside of the seat box lid - but since it's connected to -ve anyway, that does not matter.

This gives enough space for 2 x Numax batteries which are taller than most others.

Si

My numax is sat in the dip (I don't think I stood it on anything). and the negative touches the seatbox lid.

Which reminds me... you will have a PM shortly Si :)

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Just considering this myself, my two Numax don't fit, so i was planning on cutting out the tapered bottom bit and re-building it with fiberglass making it square, just keeping it above the rock slide/sill panel... P48 is brilliant stuff, very strong.

Mav

I've got two Numax in mine but arranged them to the posotive terminals are on the lower side (nearest the door) and they fit with minimal clearance for the negative terminal to the seat box lid.

Fiddly as hell but they are in there without amendmends to the bottom of the battery box to date...

Neil

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Here is mine: (Note this is a Devon4x4 Twin Battery Tray shown without the battery retaining strap)

Containing 2 x Exide Maxxima. 1 x Additional fuse box (protected by a 60amp HD fuse). 1 x Albright HD contactor / isolator, monitored by a genesis battery monitoring system.

IMG_1633.jpg

Mounted on the front is the winch isolation switch and an Anderson jump start plug outlet.

IMG_1645.jpg

Regards

Rob

Never thought I'd say this but that is one fine looking battery box!!!

Well the seat box is out the truck just now, i'll have another fiddle as to trying to get the 2 numax batteries in. - I just wasn;t happy witht the any arrangment I could work... but generally by the sounds of it, it is a tight fit anyway without modifying the battery box. Rather than buy yet 2 more batteries I think I'm going to do a bit of sculpting of the bottom of the box.

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That is neat!

Can't find a pic but as Si has said I packed the outside battery up with some wood & fitted them with the +ve terminals at the back.

If you need a pic let me know & I'll take out the bucket seat at the weekend.

Mick.

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