Odyssey PC925 Installation - LotusTalk - The Lotus Cars Community

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post #1 of 36 (permalink) Old 11-09-2008, 09:56 AM Thread Starter
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Odyssey PC925 Installation

I just changed the original battery in my Elise, which was sold new in September 2004. I've been on borrowed time, as the original has not leaked, died, or slid out of the mounting brackets.

I decided to replace it with an Odyssey PC925, as it is about the same weight as the OEM and other Elise owners seem to have had good luck with them. I wanted a mounting system that would keep it from moving around, so I bought an Odyssey aluminum mount and modified it to fit my car. I bought some aluminum bar and angle from Home Depot, then modified them to fit the Odyssey bracket. Shown below are photos from start to finish, which I'll have to show in a few posts.


Here's the bracket I purchased from Odyssey, shown with the PC925:
Name:  PC925 Mount.jpg
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These pics show the removal of the original battery and brackets:
Name:  Lotus Elise - Odyssey PC925 Battery Installation 001 (2).jpg
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Name:  Lotus Elise - Odyssey PC925 Battery Installation 017 (2).jpg
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Name:  Lotus Elise - Odyssey PC925 Battery Installation 019 (2).jpg
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This shows the size of the PC925 and brackets vs. the original:
Name:  Lotus Elise - Odyssey PC925 Battery Installation 011 (2).jpg
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post #2 of 36 (permalink) Old 11-09-2008, 10:11 AM Thread Starter
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Here's some shots of the PC925 and brackets:

Name:  Lotus Elise - Odyssey PC925 Battery Installation 059 (2).jpg
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I drilled a hole through the Odyssey bracket, then installed a few layers of some 3M double sided strips:
Name:  Lotus Elise - Odyssey PC925 Battery Installation 026 (2).jpg
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I installed this bracket on the nutplate:
Name:  Lotus Elise - Odyssey PC925 Battery Installation 067 (2).jpg
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Then bolted the bracket to the fender well. The 3M strips keep it at the proper angle so that the bracket is perpendicular to the nutplate. Also note industrial strength Velcro attached to bracket and trunk floor:
Name:  Lotus Elise - Odyssey PC925 Battery Installation 072 (2).jpg
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post #3 of 36 (permalink) Old 11-09-2008, 10:25 AM Thread Starter
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I then slid the battery in after attaching the Velcro to the bottom of it:

Name:  Lotus Elise - Odyssey PC925 Battery Installation 077 (2).jpg
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Attached the bottom bracket with nyloc nuts and washers, then secured it to the nutplate with the original fastener:
Name:  Lotus Elise - Odyssey PC925 Battery Installation 080 (2).jpg
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Attached the top bracket with nyloc nuts and washers, using 3M strips on underside of angle to cushion battery casing:
Name:  Lotus Elise - Odyssey PC925 Battery Installation 084 (2).jpg
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Attached cables:
Name:  Lotus Elise - Odyssey PC925 Battery Installation 045 (2).jpg
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and reinstalled carpet:
Name:  Lotus Elise - Odyssey PC925 Battery Installation 047 (2).jpg
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I recommend using the PC925 with the optional metal jacket, as it fits the bracket much better and is recommended for high-temperature environments. Also, I used blue Loctite on the original button head fasteners that attach the bracket to the car.

I'll probably reinstall the snaps for the carpet, then install the battery cover once I've driven it a few times and check the assembly for movement.
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post #4 of 36 (permalink) Old 11-09-2008, 10:31 AM
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Very nice. I dont think that battery is going anywhere....

I made a strap bracket out of stainless strap that hooks to the bottom and front side of the outboard original bracket and then bolts down to the spot where the in board bracket is.

I like yours better...I may change mine to one like yours.

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post #5 of 36 (permalink) Old 11-09-2008, 11:22 AM
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Why did you use the short piece of metal on the side nutplate before putting on the bracket?
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post #6 of 36 (permalink) Old 11-09-2008, 12:40 PM Thread Starter
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Quote:
Why did you use the short piece of metal on the side nutplate before putting on the bracket?
Because the rivets have a shoulder on them and would have been pressed against by the Odyssey bracket if I didn't have something to protect them. The short piece of aluminum fits snugly on the rivets and the bracket touches this plate at the top and bottom. I have some 3M double-sided automotive tape located on the bracket where it contacts this plate at the top. This allows the bracket to be perpendicular to the centerline of the nutplate threads. This is important to get right, otherwise the whole assembly will try to rotate the nutplate a few degrees and put stress on the wheel well fiberglass that it is mounted in.
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post #7 of 36 (permalink) Old 11-09-2008, 01:06 PM
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Oh, okay then .
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post #8 of 36 (permalink) Old 11-12-2008, 03:12 PM
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....looks like he's serving a long sentence.

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post #9 of 36 (permalink) Old 11-12-2008, 03:57 PM Thread Starter
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....looks like he's serving a long sentence.
I hope so! Some say these batteries can last ~8 years.
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post #10 of 36 (permalink) Old 11-14-2008, 05:02 AM
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Hey tmr........I've been out of town for a while. Its great to see that the installation went so well. I know you had it planned out pretty well beforehand, so I am glad you didn't run into any unexpected issues. This is something that I have on my "to do list" when I get the time. Hope to catch up with you soon!
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post #11 of 36 (permalink) Old 11-14-2008, 12:44 PM Thread Starter
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Quote:
Hey tmr........I've been out of town for a while. Its great to see that the installation went so well. I know you had it planned out pretty well beforehand, so I am glad you didn't run into any unexpected issues. This is something that I have on my "to do list" when I get the time. Hope to catch up with you soon!
Cletus:

Let me know when you want to do the conversion to your car. I'll PM you with details on what you need to order.

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post #12 of 36 (permalink) Old 02-28-2009, 09:09 AM Thread Starter
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Here's a few more photos, as I've had a few requests. PM me if anyone wants any additional detail or hints.

Name:  Lotus Elise - Odyssey PC925 Battery Installation 007 (2).jpg
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Name:  Lotus Elise - Odyssey PC925 Battery Installation 041 (2).jpg
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Name:  Lotus Elise - Odyssey PC925 Battery Installation 044 (2).jpg
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Name:  Lotus Elise - Odyssey PC925 Battery Installation 073 (2).jpg
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Name:  Lotus Elise - Odyssey PC925 Battery Installation 030 (2).jpg
Views: 2154
Size:  64.2 KB
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post #13 of 36 (permalink) Old 02-28-2009, 09:10 AM Thread Starter
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Name:  Lotus Elise - Odyssey PC925 Battery Installation 032 (2).jpg
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post #14 of 36 (permalink) Old 03-18-2009, 08:22 PM
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Slights mods to this excellent design

Slight mods to the original design shown:

Non-welded angle clip using counter sunk machine screws.
Back has Riveted on fender well Alum. spacer to level box
Speed nuts for holding on upper and lower straps make removal easier.
Inside corner Alum. spacers to allow battery to clear head of fender well screw.

5 hour layout, fabrication, and install time including trip to Home Depot for materials.
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post #15 of 36 (permalink) Old 03-19-2009, 07:28 PM Thread Starter
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Looks great! Post a few pics of it installed if you've got 'em.
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post #16 of 36 (permalink) Old 03-25-2009, 03:17 PM
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Install photos

I went through an autocross tech last weekend and they said this is one on the best battery hold downs designs they saw. I did have a problem with the stock hold down battery movement and one case where it was rolling around in the trunk, but that's gone now. Thanks for posting the original design. This site is a good resource for saving time with non-recurring engineering.
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post #17 of 36 (permalink) Old 03-25-2009, 03:26 PM Thread Starter
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I'm glad this worked out for you, especially on a car that gets regular autocross time. I'm an engineer by trade, so I tend to go nuts on stuff like this if I can't find a readily available solution.
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post #18 of 36 (permalink) Old 04-16-2009, 09:32 AM
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I needed a new battery this spring so I went for the PC925 and bracket as well. For the most part I pretty much copied exactly what you did. I found some of that ribbed rubber mat and layered it all around the bottom and sides of the battery. I also cut notches in the angle piece so the snaps still function. This setup is so solid. I'm very confident.

Thanks for the great idea tmr!
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post #19 of 36 (permalink) Old 04-18-2009, 03:38 AM Thread Starter
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I'm glad this worked out for you, as the ribbed material sounds like a good alternative to velcro. The only thing you might want to consider is using a metal jacket, which you can buy separately and secure to the battery with clear silicone.
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post #20 of 36 (permalink) Old 04-20-2009, 04:13 PM
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Okay, I hope I don't sound too much like a girl here. What is a metal jacket? I'm looking on the Odyssey website and I am guessing that I need to buy PC925MJT, their aluminum battery mount, and the additional parts in the picture from the hardware store. And I have someone who can weld the angle piece for me because I *think* that is the only thing I can't do. Sound about right?

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