Tonight, I worked on Battery Tie-Downs, insulating the front batteries, and getting the bumper back on.
I cut two scrap pieces of unistrut to go across the top of each battery. Drilled a hole straight down, for threaded rod to go from the unistrut down through the battery tray to bolt it down.
I used 1 inch foam directly on the battery tray to insulate under the batteries. Then I "sculpted" 2" foam to fit around the batteries as best I can.
The batteries really fit in pretty tight because of the shape of the headlights and other parts that poke into that space.
I did have to carve down a lot of edges to make it work. A Japanese pull-saw works great to cut foam, as does a drywall "stab-saw'.
I used some HVAC duct tape to connect all the edges of the foam and seal it up.
After all that, I got the bumper back on, and then the bumper cover. However, I discovered that the bumper cover really installs from the inside, which is now totally blocked by the batteries and foam!
I was able to at least get two screws in the ends, so the bumper cover should stay on for now at least.
I do still have to modify the "guppy mouth" a bit, as the tow bar brackets came to the very far corners of it. Will have to cut away at it a bit more...
Hope that keeps the batteries warm for the winter!
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