Today I dismantled an old PC CD-ROM drive that had failed and was waiting to be disposed of (admittedly I’d already had the internals out to see if I could fix it previously so it was just the fascia and metal cage).
This cage I then hacksawed to create a small flat rectangle of metal.
I then went under the car to remove the two battery clamp holder captive nuts, one of which had bent down in being drilled out during the last time I worked on the car (taking part of the underside U-bracket with it). This came off by wrenching and twisting with vise-grips.
The second was much more of a pain (my skinned hand can testify to this). In the end it was a mix of socket set, hacksaw and vise-grips to twist, break, tear and shred it from the car. It came away in various twisted pieces, however the center of the U-bracket appears not to have rusted like the rest and refused to come away.
So it was on to using an electric drill with a wire wool attachment to get rid of the small jagged lumps that made up the twisted edges of this center piece. It didn’t work so tried a grinding stone attachment which did nothing, then discovered the drill was at lowest setting and it wasn’t just nearly out of battery - then things went better with the wire wool, stone etc. till it was a bit smoother but still too lumpy for the new bracket to sit over it.
A 4 pound lump hammer was then applied which did a much better job of getting things smooth enough for a new bracket to go in place, and hammerite applied to the whole area.
And the current space limitations, this was all done with the wheels on and the car on the ground which makes for fun crawling.
I then used the battery clamp to mark on the new bracket where to drill the holes and drilled them out, mid way through the battery on the drill ran out and I knew the other battery had failed. Turned out it hadn’t failed, the earth contact had rusted! on the battery (which was stored in the house ) so emery cloth got it going - very well in fact and the holes are now drilled.
Then it was painting time, so I tied it up from the clothes line and proceeded to paint it with a supermarket plastic fruit bag (I had done this for painting the underside too). This would have gone well if not for it suddenly spinning and my foolishly steadying it with my non-bagged hand, and of course not on the not-yet-painted bit (just to add, hammerite killed the only brush I had the last time I used it by wrecking the bristles, hence the painting with a plastic bag - also finding your normal painting gloves full of water and woodlice kinda makes you look elsewhere…).
Result, at least an hour trying to get hammerite off my hand.
Although the bracket (currently line-drying) is flat, I’m hoping that since it’s of thicker metal than the U-bracket that its replacing and slightly longer, in addition to washers will make it as sturdy for keeping the battery in place. I did intend on tapping the edges in to convert it into a U-bracket, but I have nothing to hold it in place properly, and while I did try I just couldn’t hold it and hit it with enough force to do it properly.