Topic: Billet battery box

[EBCB]

I hate to use the term "billet" because it isn't, but it is hewn from solid bar stock - so close enough. Like most billet parts, it's taking an OEM $15 part and making a $75 part out of it  . But it's fun as well.


Anyway, here's the CB550 OEM battery box in all it's glory:


Rusty and nasty as you like. Time to make it look a bit better!


I started by cutting 3 blanks for the bottom and sides, then squared them up and milled them to the proper width:



Then drilled the holes for the rubber grommets / bumpers to fit in;



Milled the taper on one end and we have a completed bottom section;

[EBCB]

Next, I milled the sides;



Had to put a slight bend on the one side.

Turned a couple of bolt spacers on the lathe. Need to make rubber inserts for them so that the battery box is rubber mounted as Honda intended it to be;

[EBCB]

Milled and drilled the cross members that hold the rubber straps next:





And that was about it for today. Next I need to make a fixture to hold all of the pieces in place while the pieces are TIG welded together. Should be easy enough. Then I'll have a new battery box and save myself a whopping $15 

[kghost]

Nice work very well done

[EBCB]

Wow nice box. Where did you get the mill?

Old750 - I have a CNC mill as well as a manual mill in my spare garage. Also have lathes, brakes and other stuff out there. Metalworking is a hobby of mine.

kghost - thanks!

[dusterdude]

cool hobby

[EBCB]

cool hobby

I keep tellin' my wife that....

[Bodi]

Tiny warning that battery acid really attacks aluminum. It takes the paint off steel leading to rust but aluminum is actively eaten away at.

[EBCB]

Yup  - I'm aware of that. Means I'll get to make another one someday

I also want to make one for a smaller sealed gel type battery, that'll be next. Should eliminte any leakage problems.

[Andoo]

Nice work, I want a mill 

[EBCB]

I keep saying that the first thing I buy after buying my first home will be a mill and a lathe. Skip the furniture. Oh the joys of being caged in an apartment...

There are lots of Chinese made mills and lathes out - and most are pretty cheap to buy. Problem is, their ability to hold any tolerance is pretty cheap as well. There is also tons fo good used Bridgeport mills (USA made) and other brands of lathes as well. Decent mills can be had for about $3,000 if you shop around, lathes are a bit less.

The associated tooling is where you'll go broke There's simply no end to the bits, holders, grinders, clamping devices, measuring tools, that you'll need. Like bikes, it can be a huge money waster - but it's just as much fun.

[nickjtc]

I have a CNC mill as well as a manual mill in my spare garage.

We're not worthy! Spare garage, indeed!

[old750]

Purchasing a mill wont be a problem. Finding a garage to put it in is the problem here in Vancouver. Average price of home here is 400000$ but realistically you can't find anything decent in the actual city of Vancouver for less than $500000. Northern Ontario here I come (soon)!

I had a mini lathe with mini milling head by Sherline in my apartment in Ottawa. Also had a grinder, mig welder and a bunch of tools. My 50 year old building was major fire hazard. Now I live with my GF and she wont tolerate a filthy shop for an apartment. Such a shame... all this open space in the living room.

-Alex

[MoTo-BunnY]

Purchasing a mill wont be a problem. Finding a garage to put it in is the problem here in Vancouver. Average price of home here is 400000$ but realistically you can't find anything decent in the actual city of Vancouver for less than $500000. Northern Ontario here I come (soon)!

I had a mini lathe with mini milling head by Sherline in my apartment in Ottawa. Also had a grinder, mig welder and a bunch of tools. My 50 year old building was major fire hazard. Now I live with my GF and she wont tolerate a filthy shop for an apartment. Such a shame... all this open space in the living room.

-Alex

lol. . . u need a girlfriend like me then. My place is full of clothes, clothes, and more clothes plus all my sewing stuff. . . tools and bike project stuff. .  .cookware. .  . guitars. . . and computer/tech stuff.  . .    he he he   a Jane of all trades   

then again, I'd always be wanting to borrow your MIG welder. . . .

[Steve F]

Purchasing a mill wont be a problem. Finding a garage to put it in is the problem here in Vancouver. Average price of home here is 400000$ but realistically you can't find anything decent in the actual city of Vancouver for less than $500000. Northern Ontario here I come (soon)!

I had a mini lathe with mini milling head by Sherline in my apartment in Ottawa. Also had a grinder, mig welder and a bunch of tools. My 50 year old building was major fire hazard. Now I live with my GF and she wont tolerate a filthy shop for an apartment. Such a shame... all this open space in the living room.

-Alex

lol. . . u need a girlfriend like me then. My place is full of clothes, clothes, and more clothes plus all my sewing stuff. . . tools and bike project stuff. .  .cookware. .  . guitars. . . and computer/tech stuff.  . .    he he he   a Jane of all trades   

then again, I'd always be wanting to borrow your MIG welder. . . .

OMG!  Do you have a Sister?   

[EBCB]

Purchasing a mill wont be a problem. Finding a garage to put it in is the problem here in Vancouver....

I hear ya. My home has a 2.5 car on one side and a 1.5 car adjacent to that - the doors are 90 degrees to each other. The 1.5 car is crammed full of machine shop crap. I really need to find some shop space someplace. I have to shuffle motorcycles from one garage to the other just to work in the machine shop. Hope to find someplace this winter. Should keep the wife happy as I'll no longer be tracking aluminum shavings into the house.

Moto-Bunny : What kind of guitars? I have a room full of them as well.

[MoTo-BunnY]

Moto-Bunny : What kind of guitars? I have a room full of them as well.

where do I start?  lol   I have a '70 Gibson EB-O bass (my first one), a Minarik Goddess (awesome Gibson-esque guitar - Minariks are really really cool. . .), an old early '80s Les Paul copy (lawsuit era), several acoustics, and a nice Romanian violin, to boot. .  . lol. 

Always been into the Gibsons - I grew up like 15 minutes away from where the original factory was in Kalamazoo!   

[EBCB]

Funny - I have a '83 Gibson Explorer Bass. Things weighs so much that it's difficult to play it for very long without taking a rest.
Also an ESP Custom, ESP baritone, Ferrington acoustic, Fender strat and a Fender Tele and fianlly a Tokai strat.

Can't play any of them worth a crap though