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Attempting to source or fabricate replacement battery cover/insulator
The battery cover - air inlet assembly extends the life of the battery by insulating it from engine heat soak.
A majority of LS400 plastic battery covers have become brittle and warped over time and are discarded.
Mercedes Benz located their batteries behind the firewall sound barrier...
The battery was insulated from all engine heat and (mine) lasted 9 years.
With Mercedes as the car to beat and compete, unsure why Toyota placed the LS400 battery as it did (later corrected on LS430), but was aware of the location problem....hence battery cover and cold air inlet scheme.
Fast forward....
Lexus improvidently discontinued this insulating cover so am interested in locating one in reasonable shape for forum.posting on fabrication options
Anyone with a spare cover?
Please P.M.
Thanks.
Item.4 is ram air battery cooling inlet and item 8 is cover
Car battery (life).expectancy zone suggests heat reduces battery life. Unclear if this chart takes into account battery location.
Acquired a spare battery cover for $3 from a recycling yard in reasonably good condition.
The rear side closest to engine has become warped from heat soak.
Am seeking recommendations on best technique to apply heat to iron out the waves.
Have considered clamping two heated metal plates over the sides to flatten them out..however not sure best temperature heat to apply.
After straightening will treat the backside with DEI brand heat reflecting foil to prevent future warping.
Upside down view of cover depicting distorted plastic side...distortion rides up about two inches from bttom. Topside image of battery cover. Plastic is pliable and not brittle.
Lexus employed a plastic battery cover with a ram air cooling scoop to extend battery life.
The plastic cover is subjected to radiant heat and heat soak which warps the cover.
I managed to smooth mine out with a steam iron and tinfoil between iron and plastic box.
After cleaning with alcohol, applied DEI brand Reflect-A-Cool heat barrier with high tack pressure sensitive adhesive.
Used paper templates to create perfect fit and it looks OEM.
The reason for adding reflective heat barrier is to preserve the OEM plastic cover which is discontinued, and further reduce heat sink to the battery.
DEI Reflect-a- Cool.. The There is an air gap between the plastic cover and battery so this is used to reflect heat away. On shutdown, everything underhood cooks.
For those who no longer have the OEM battery insulator, DEI also offers a battery insulator kit OEM battery box before application of DEI thermal material Prepare paper template Cutting an X in the material.over the cutous. Fold over to the backside Cover has a clamp for positive battery cable. Clearance cutout is required. Material.installed. Glove fit Finished product.. Replaced OEM.foam.with EPDM from McMaster-Carr Installed Battery life expectancy for lead acid battery vs temperature. This chart suggests underhood heat significantly reduces battery life...which explains why Toyota used a battery insulator in LS400
Very cool Yodaone....keep up the good work and thanks for sharing. Very informative as well. I will be looking for a battery cover and if i can find one then i will be doing this mod on my LS and other vehicles to extend battery life.
04-04-19, 07:36 PM
Plastic battery cover
