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  #1  
Old 12-03-17
Seigried Seigried is offline
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Default Gen 4 battery tray fix

Here is how if fixed my broken tray, you need a tray and -

saftey-
disconnect the battery and remove
eye protection

The whole job took about 2 hours over 2 week days + time for the paint to dry. If you choose to not repaint the metal tray then 2 hours.

1- photo 1 & 2 Disconnect and remove battery, various tools are required as well as a suitably sized rivets and a battery tray
2-photo 3 the unmodified tray is a good fit but does not sit flat.
3-photo 4 & 5 using my dremmel style tool I marked out and cut some holes in my tray to allow access to the factory tray bolts.
4-photo 6, 7 & 8- on one side the little side tabs need to be cut out to allow the tray to sit flush
5-photo 9 - The ends of the factory tray also need to be cut to allow the tray to sit flush
6-photo 10 - tray sitting flush
7-photo 11 & 12 - tray showing rivet locations underneath the factory tray and the new metal rivets done
8-photo 13 - final product bolted back in place

If i did this again I would make some of the holes in the metal tray larger making it easier to access and tighten the factory tray bolts.
Attached Images
File Type: jpg 01-tools.jpg (152.7 KB, 179 views)
File Type: jpg 02-rivets.jpg (137.2 KB, 180 views)
File Type: jpg 03-unmodified tray.jpg (133.7 KB, 194 views)
File Type: jpg 04-modified tray.jpg (98.2 KB, 182 views)
File Type: jpg 05-mod tray inplace.jpg (83.4 KB, 177 views)
File Type: jpg 06-tab to cut.jpg (91.0 KB, 173 views)
File Type: jpg 07-cut tabs.jpg (96.0 KB, 178 views)
File Type: jpg 08-cut tabs 2.jpg (126.1 KB, 178 views)
File Type: jpg 09-trim at bottle.jpg (69.0 KB, 167 views)
File Type: jpg 010-test fit.jpg (73.7 KB, 170 views)
File Type: jpg 011-rivits under tray.jpg (154.5 KB, 178 views)
File Type: jpg 012-rivits in place.jpg (127.9 KB, 174 views)
File Type: jpg 013-tray in place.jpg (116.5 KB, 174 views)

Last edited by Seigried; 12-03-17 at 07:46 PM.
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Old 12-03-17
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Lando Lando is offline
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Looks like a good fix!!
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Old 24-02-18
Seigried Seigried is offline
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One year on and 10,000km. Not loose at all, only dirtier.

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Old 24-02-18
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Dicko1 Dicko1 is online now
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Good job. I,d go for steel pop rivets though. Have had a few items crap out because of alloy pop rivets.
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Old 25-04-18
cooperplace cooperplace is offline
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where did you get the metal tray from?
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Old 25-04-18
Seigried Seigried is offline
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Supa cheap etc all carry them.

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Old 25-04-18
cooperplace cooperplace is offline
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thank you
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