THE BATTERY TRAY

For no particular reason I fancied moving on to the battery tray next.  It was obvious that I was going to need new battery straps as these had been cut off at somepoint

Before I can decide how best to replace the battery retaining straps I need to know what battery I am going to fit.  I have two alternatives, fit a genuine Lambretta battery or a modern alternative.

I contacted Lee at Scootopia, (was Casa Lambretta) (they really are so helpful) and he went away and measured a real Lambretta battery for me, W 125 - D 35 - H 127.  I trawled the internet and found a number of reasonable alternatives despite them being larger in most cases.  I liked the YUASA battery at Allstyles-scooters for £30 ish with a size of W 122 - D 46 - H 125 and a capacity of 7Ah.  I could now make some decisions.

Non standard tray with straps cut off

I was suspicious of the plate at the back as it was made of much thinner material than the rest of the tray.  The tray was a lot wider than the Lambretta size and when I removed the rubber mat in the bottom of the tray I could see why.

The tray had been modified by bending the back flange down and attaching a thin plate.  I guess to accommodate a non standard battery.  I can see the sense of this as Lambretta battery is very expensive at around £70.  


I need to decide what standard I'm trying to achieve.  If Concourse I will have to have the correct battery, if not I can use a cheaper alternative.  I think the non concourse route is the one for me.   

My original concern to have any welding completed before I filled the tank with fuel included fitting new battery straps.  This problem was solved when I discovered that the battery tray is removable, I had thought It was welded as part of the frame. It is in fact attached to the frame by two screws.  With the paint removed I was able to drill out the rusted screws and release the tray.

I have subsequently been able to buy from Terry, a contact, an original battery tray so I now have the opportunity to revert to the correct battery and tray configuration if I change my mind at a later date.

The top tray is from my scooter.  The original battery strap can be seen in the base of the tray where it has been cut off what was the side.  Even the extended back plate has evidence of a strap that has been removed. 

The lower tray is an original  that I bought  just in case I ever wanted to fit an original battery.





I intend to rebuild the extended tray to make it like an over sized original.  This has the advantage that it gives me a wider selection of cheaper batteries.  I eventually ordered the battery from Allstyles Scooters (B396-6) at £29.95 (I was subsequently told that a similar battery should be available for around £15, do I feel gutted?).  With the battery available I was ready to work on the old tray and the battery restraining strap.

I first I removed the tall back plate and the old ends of the retaining straps. The backplate was replaced with a strip of material the same width and thickness as the other three sides to complete the tray.  With this welded into position I could start work on the retaining straps.

I had previously looked at as many pictures of the original strap configuration as I could find.  There seemed to be a number of options.  I liked the idea of replicating them as far as possible but once I found that there  appeared to be no definitive solution I decided to develop my own.  I liked the idea of being able to fold part of the outside strap down to allow the battery to be more easily removed.  (a bit daft actually because I'm unlikely to ever remove the battery once the scooter is running but it was a good idea at the time).

I hate using tin shears to cut thin sheet.  It always results in the bit you want being twisted like a piece of apple peel.  Despite trying to flatten the material it is never quite right.  So without access to a guillotine I resort to my other favorite technique - the hacksaw.

This may be a bit slow but with the sheet securely clamped and using a fine toothed hacksaw blade at least you end up with a nice flat strip of material.  

The finished battery tray and strap.  the folded down section makes for easy fitting of the battery.  The original straps are spot welded to the tray.  I had visions that if I ever wanted to transfer my straps to the other tray welding was not an option.  I therefore elected to tap M3 threads into the tray sides and secure each strap with two M3 roundhead screws.

The tightening of the strap uses a pair of trunnions and tray screw purchased from Allstyles Scooters.  The trunnion on the right has a clearance hole whilst the one on the left is tapped M5.  The spacer between the head of the screw and the trunnion is because the head rubs on the strap.  I'm not too sure I like that but I can always turn down the head of the screw if it continues to offend me.

The final assembly fit well inside the scooter frame and does not touch anything.   I have to say that the actual "clamping" of the battery is adequate but not exceptional.  The battery will not fall out and should not move too much but I may have to adjust the trunnion position so that I can further tighten the strap.  If I apply this to the outer trunnion I may be able to dispense with the spacer which would be nice.



 i think I need to start thinking about the harness soon.  I seem to have a lot of wires in place where I wasn't expecting them.  I also need to find a way of providing a stop light switch.  Still more fun to come.