I’ve hit a road block with my golf cart – the battery tray is completely rusted out and I’m at a loss. It’s seriously affecting the performance and safety of my cart. Has anyone tackled this issue before? What are the best fixes or replacements for a rusted battery tray?
Response
I faced a similar issue with my golf cart. The battery tray was a rusted mess. I ended up fabricating a new tray using angle iron and gave it a good coat of rustoleum. It took some effort but was a solid fix.
Solutions that Worked for Users
| Solution | Users Who Found Success | Approx. Cost (USD) | Approx. Time Needed (Minutes) |
|---|---|---|---|
| Fabrication with Angle Iron and Paint | 2 | $20 – $50 | 60 – 120 |
| Using Corroseal for Rust Treatment | 1 | $20 – $40 | 30 – 60 |
| Fabricating Using Old Bed Frames | 1 | $0 – $30 (if materials are on hand) | 60 – 120 |
Symptoms
- Severe rust and deterioration on the battery tray.
- Unstable and unsafe battery placement.
- Potential risk of battery damage or failure.
Possible Causes
- Long-term exposure to moisture and corrosive battery acid.
- Inadequate maintenance and cleaning in the battery compartment.
- Use of materials prone to rust and corrosion.
Solutions that Worked
1. Fabrication with Angle Iron and Paint
- What I Did: Created a new battery tray from angle iron, followed by rustoleum coating.
- Outcome: A robust, rust-free battery tray.
- Personal Experience: Required some welding skills but was a durable solution.
- Steps:
- Measure the old tray and cut angle iron to match those dimensions.
- Weld the angle iron pieces together, ensuring all joints are strong.
- Sand any rough edges for a smooth finish.
- Thoroughly clean the tray to remove any grease or dirt.
- Apply a coat of rustoleum evenly, covering all surfaces.
- Allow the paint to dry completely before installation.
- Expert Tip: Regularly inspect and touch up the paint to prevent future rust. Ensure the tray is securely mounted to avoid vibrations that can weaken welds.
2. Using Corroseal for Rust Treatment
- What I Did: Applied Corroseal to neutralize and convert the rust.
- Outcome: Successfully halted rust progression.
- Personal Experience: Easy application with effective results.
- Steps:
- Remove loose rust with a wire brush.
- Clean the area with a degreaser and let it dry.
- Apply Corroseal with a brush, ensuring even coverage.
- Allow it to cure as per the product instructions.
- Optionally, apply a topcoat for additional protection.
- Expert Tip: Apply in a well-ventilated area and wear gloves for safety. Regular checks can help catch new rust spots early.
3. Fabricating Using Old Bed Frames
- What I Did: Repurposed bed frames to construct a new tray.
- Outcome: An economical and sturdy solution.
- Personal Experience: A creative and eco-friendly approach.
- Steps:
- Disassemble the bed frame and sort usable parts.
- Cut the frame to the required size, considering the battery dimensions.
- Weld the pieces together, checking for stability.
- Sand and clean the new tray.
- Apply a protective coat of paint or rust inhibitor.
- Install the tray, ensuring it’s firmly secured.
- Expert Tip: Test the tray with batteries to ensure it can support the weight. Consider adding reinforcement if necessary.
Golf Cart Models Where This Worked
- Various models, including EZGO and Club Car.