In the quest for better cold weather cranking and in anticipation of a snow plow install; I looked into bigger and better batteries. I've used the Optima brand in other vehicles and been pleases with the results. This is going on a 1997 Suzuki DD51B. My first choice was to make as few mods to the existing battery box as possible to make the job go easier and faster. I settled on the Optima model D 51. Specs here: http://www.optimabatteries.com/_media/documents/specs/D51_D51R_082004.pdf This battery will just fit in the existing battery box in a vertical install. Here's how I did it: Cut a slot in the battery tray slightly larger than the diameter of the neg terminal. Then I took a grinder and rounded out a hole that the plastic flange on the battery would fit through. Here's a close up: Next I replaced all the existing cables and connectors to up the size of cable and do away with any old corroded bits. I put a 3/8" thick closed cell foam pad on the left side of the battery and behind to keep it from chafing on the frame. I'd like to find a small nylon strap to tie it down over the top, but it really isn't going anywhere as it is now. Here's the overall of how it looks: Total cost was just under $200 for battery, cable and wiring. It cranks great! runs the dump box and plow well.
Also found this way cool looking custom battery tray on ebay: http://cgi.ebay.com/ebaymotors/Ball...0011033?pt=Motors_Car_Truck_Parts_Accessories I'm not that into looks, but the quality looks top notch. Kirk
Just weld up your own battery tray: It took me all of 1/2 hour with my angle grinder and wirefeed welder... I just used a standard car battery inside a marine battery box for mine. I'm not rich enough to buy an Optima battery
Yes, fabbing stuff opens a world of options. Point of my approach was to get an easy install of a deep cycle no excuses cold start battery. 10 minutes work and I don't have a welder anyway. This worked out great for me. Otpima isn't too bad long term. Lasts at least 3 times as long as a standard battery. Kirk
Before that I just had the battery box strapped to the frame of the truck without any fabbing... and my welder cost less than your battery! Optima makes a kick ass product no doubt and I'm sure it'll last you a good long time. Nothing worse than that sinking feeling when you come out of work on a cold day and the truck just won't turn over. :/
I'm on year 9 of an Optima in one of our cars and it's still going strong. I just bought one to replace the original battery in our 2003 Subaru. Even though it cost twice as much as the store brand battery (and is actually warranted for half as long) I have no doubt it will probably be the last battery I buy for that car. Nice job on BOTH of your battery trays. I'm going to have to do something like that soon myself as my little stock battery has pretty much decided that it wanted to take the winter off.
Got my first optima in my truck. Been in the truck for over 18 months and have only cranked it up once every 3-4 months for a short period of time. Im impressed so far. I only reason I really got it was so I could lay it on its side. Hope it holds up! -Greg
Next time may want to try the batteries from the company that starts with the letter "O". Odyssey. And do some research on Optima and Odyssey online. There really is a big difference and we left Optima years ago. Just saying, when your back in the market for a battery. P.S. There are Odyssey batteries that fit upright and normal in the Suzuki battery space (PC680 if my memory serves me right). You can salvage the original cable ends connectors with these too as the clamp mount bolt holes can be screwed right to the Odyssey posts.
