3D Printed Ford Battery Case Help

[WarbirdPhotog]

Originally Posted by ford38v8

When I built mine, I used an original Repop Ford LF battery. After neutralizing the acid with baking soda, I set it in the sun to melt the tar top, then scraped out the tar with a screwdriver to save for reassembly. The 3 individual script lead connectors were salvaged, as were the filler caps. The remnants of the top was removed, the internals gutted, and the bottom cut out. The new top was made from 1/16" ABS, with the 3 cells of 3/16' ABS welded on with ABS solvent. Holes to match the Optima were cut, lead connectors secured in place, the new top secured permanently in place with epoxy, with the salvaged tar reapplied. The new Optima gets it's hold down tabs trimmed and goes into the faux case from the bottom, the posts exit on top as original. Appearance is perfect, no Concourse Judge able to detect any difference from original.

A newer version of the Optima required smaller post holes in the top, which was accomplished by masking the larger holes with red and green felt acid neutralizer washers. If making one today, the post holes can be correctly sized, negating the need for the red and green acid washers.

The newest version of the Optima now requires a case 3/8' taller than a Ford LF. A simple 3/8' thick platform supports the faux battery, while the Optima projects down inside a hole in the platform. No such need for this platform with a Ford HF battery, as it fits the new Optima without additional heightening.

I cannot supply pictures of my converted battery as sadly, I have sold my Ford, and the Ford LF battery went with it.

I hope to basically design the final product around the optimum versus the other way around. So that's why what I'm building right now is modular so it can be adjusted for the optima once I get one. I want to try and get it as close to a perfect fit as possible. I'm going to explore different methods of putting it in with and without the feet and see how that compares. If it turns out it needs to be about 3/8" taller than the original, then I'm okay with that.