Fiberglass Battery Box Lid Extension

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fountain27

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exMember
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Jan 13, 2006
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19956
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I want to add a pair of golf cart batteries to my current battery configuration. The gc batteries are taller than my normal batteries so I need to make my figerglass battery box lid about 3" taller.

The box is solid fiberglass. What is the best way to add a few inches to the box lid? Just wrap a few pieces of glass, sand, paint? Thanks.
 
Other than needing something to support the wet glass, that's it...
 
Corrugated cardboard and Duct tape would be my first choice; but whatever works for you. Wax it liberally with some kind of paste wax or the fiberglass will stick to it.
 
MDF works great for a quick fiberglass mold. Make a 4 sided MDF box around the bottom of your cover. No sharp corners...fill all sharp inside corners with putty. seal the mdf with a spray primer then wax very, very well. Then spray with PVA mold release (several light coats). Brush on gel coat and let it set then layup fiberglass mat. You can add a ply of fiberglass cloth to make it stronger. Oh, you will have to overlap some fiberglass from the extension onto the inside of the existing cover to integrate the 2 pcs. together with some strength. Make sure you sand the inside of the cover so you get a good bond. BTW, it may be quicker and cheaper to buy a new battery box.
 
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