Delco Battery Topper

I have been thinking about getting one of these for some time. They are a cheaper alternative to the AC Delco reproduction batteries that don't seam to last more than a season. I had one years ago for a Camaro, but for some reason they won't hold a charge. These are $56.00 incl. shipping and look great for what they are. The reproduction Delco batteries are $300-350.00! I bought the extra battery terminal extenders, which I modified for a more original look. I didn't take pictures before the modification, but I will take one off and post a pic of what I did. It turned out pretty good and with the the Exide sticker taken off the modern battery it is hard to tell it's a cover. With the post extenders installed and the cables on, the battery is fully functional. They will fit any Group 24 battery. A friend bought a lesser quality one called a Tar Topper, but these are far superior in looks and quality for almost the same price and they are a licensed GM Restoration approved item. He saw mine and ordered one of these.





I have some 3/32" black ABS plastic sheet from Tap Plastics, to make a box with some laser etched "DELCO" script on the side to make it appear more original. These pictures were taken in the dark, but you get the idea. The owner of Legendary Batter Toppers, Carl, is a very nice gentleman who helped me with what I was looking for. The correct battery for the '59 is a DC 12 Delco battery with the plain yellow caps, but I got the one "delco" letters in black instead. He explained it doesn't matter which one you choose, it's really a matter of choice what you prefer. They can be found at: .www.batterytoppers.com


My car is far from "restored", but the battery cover adds to the origianlity of the car the way it is. I have pondered whether or not to do a full restoration. Some say I should, while others say leave it as is and just show it that way. Cost is not an issue, since I do this sort of thing anyway. To tear it down and have it in pieces for the next 2-4 years takes a way from the fact that I enjoy driving it too much to do that. I was thinking more of a frame-on cosmetic restoration on the outside (maybe even leave Grandpa's dents)and redo the interior for aesthetic's and call it good. However, I may give in to the masses and someday knock it down and restore her to showroom condition. Just not right now. Like I said, I enjoy driving it way too much.


Before anyone catches it, I know the Plymouth RoadRunner horn is not correct, but more for whimsy. My 4 year old insisted I put it on, it is his car, so HE says! Yes, it does sound like the "real" roadrunner!

Chad.....Wow, great minds must think alike. I bought the same topper for my car, and the Exide battery too. When I was hitting the shows with my Firebird, I was a little embarassed by the green Interstate battery in an otherwise detailed engine compartment. I saw another Firebird with one and asked the owner where she got it. She gave me the web sight for Legendary. I was looking for the R59 topper (the one with the Delco Eye,) and found he had all the earlier types also.

I would be interested in the details of how you make the box (materials and construction.) I've got a big yellow Delco sticker that I got off E-bay. I was going to put it on the side where the Exide sticker was, but I'd have to buy a new one whenever I needed a new battery. Your idea would resolve that. If you can figure out how to make it flush with the flange of the topper that would add to the authentic look. For our purposes it only needs to be one side and both ends. as the other side isn't visible. This would also make it easier to get on and off.

Funny story.....About four years ago, I was walking around the Carlisle swap meet. I had made up my mind that I was going to bite the bullet, and buy two reproduction batteries (one for the Catalina and one for the Firebird.) I planned the day that I would end up at the "Antique Auto Battery" booth. I ordered both batteries, and the lady sent her helper back to the truck to get them. I'm standing there with my credit card in hand, while she writes up the order. I ask her if the're already charged or do I have to charge them. She replies that they are dry, and I need to also buy the acid at $6 per battery. I put my credit card back in my wallet, and told her that at $275 per, without the acid, it's just lead encased in a rubber box. When you're spending $550 another $12 isn't going to break the bank, but it's the principle. She wasn't happy, but in retrospect I am......John

Chad.....A little philosophical thought. You are fortunate in the fact that; one you have a good car to begin with, and two the car has special meaning for you. I wish I were able to have my original hand-me-down coupe back. I'd gladly trade even up this one for that, even though the convertible is probably worth 4 times as much. My parents had many nice cars over the years. After their Pontiac dealer friend retired and closed up, they bought Oldsmobiles and Buicks and even a Cadillac, but the one car that they remembered fondestly was their 59 Catalina. Que Archie and Edith singing "didn't need no wellfare state, gee wasn't our old Lasalle great." My thought would be to make sure the car is mechanically in good condition, then do the cosmetic restoration as time and finances permit. Keep in mind that your grandfather, if like many of us, was most proud of that car when it was new, and up to the point that the ravages of time began to take its toll. Repair any rust, take out the dents, and single stage in the original color. That's what I'd do, but I agree that a full restoration won't add to your enjoyment, and after all, isn't fun what this hobby is about.

Let me know what the trim number on your cowl tag is, and I'll decode the description from the Master Parts Catalog, and the Dealer Album. The vinyl material is not hard to come by, as new material can be dyed to match. The cloth, in the correct pattern and color on the other hand, may be more difficult. You should begin to look for it now, even if you don't plan to do the interior for a while. I doubt that anyone would bother to reproduce the woven pattern. There is a company near you in Canby called SMS who may have some bolts of NOS fabric. They were able to supply me with all the material, with all the correct embossing that I needed to have my seats done by a local upholsterer. They don't make the seat covers, just the material. What they do make is the complete door and quarter panel trim, and it is an excellent perfect reproduction, with the right colors and embossing. Being a convertible though, mine was all vinyl. Check them out for the cloth you will need. The door panels are pricy, but the quality is great......John

P.S. I have no idea how close Canby is to you, but it's a hell of a lot closer than to me.

P.P.S. "fondestly" is that a real word?????

John- I couldn't agree with you more! The sentimental value for outweighs the monetary factor, in my opinion. I have gotten the car in great mechanical condition that allows me to drive almost anywhere and she starts everytime I turn the magical key. It does have its little bumps and bruises and obvious quirks, but for a 52 year old girl, she looks pretty good. As far as rust goes, there is only a few spots where it has rusted through, which totals to about 5 square inches on the whole car. Pretty lucky since it rains in Oregon about 200 days a year and the car was stored outside most of her life.

Cars usually don't rust out here, unless you don't take care of them. Salt is not used on the roads in the winter, they use sand instead. Magnesium Chloride has been used in the last 8 or 10 years, but the car sat for most of that time. MC is corrosive if left on a car and wreaks havoc in aluminum wheels, but not if it is rinsed off frequently. Funny, you mentioned SMS. They are not far from me at all. I sent an email with all the pertinent info a few month's ago (style: 2119, trim: 201, Paint: HH, Acc: DT) and they sent me an envelope with samples of everything need to trim the entire interior! The colors and fabric patterns match perfectly. The Pasadena Grey woven pattern for the seats is a spot-on match, since apparently it was used just about every GM model for '58-'63.

The door panels are also spot-on matches of the originals, right down to the embossing. The price is right, too. I need to replace the both front and rear window rubber, before a new interior goes in, but for the most part I can polish this diamond in the rough with just a some cosmetic restoration and I will be happy to drive to a cruise-in or show. I'm actually happy showing her just the way she is....I get plenty of thumbs up (and dash plaques) for originality and the fact that she is a true as-found survivor. That is far higher on the cool-factor than a trailer queen or Sunday driver as far as I'm concerned! My other Grandpa Wes, who had a white '59 Catalina, exactly like this one, always said cars are meant to be driven, and that has stuck with me all these years. Wes died when I was 10, but he was and still is my best friend! My Son, who is turning 4, is named after him and I will share all of my fond memories with him as he grows up.


Grandpa Wes was pretty well known around here and elsewhere. He was the Chief of Police in the the small town I grew up in, Fairview, Or. In his early days he was a Portland Police Patrolman, who in the 1950's was catipulted into the spotlight involving a traffic accident that changed his life forever.

He was dispatched to the scene of a pedestrian being hit by a car. When he arrived, He checked the victim and ran back to his car to radio for an ambulance, in the mean time, he had witness cover the victim, whom was still alive, with a blanket. Keep in mind this was the 1950's, so no first responder stuff, here. It was his duty to tend the victim first, call an ambulance second, then deal with the perp, which he promptly arrested, due to witnesses at the scene said he was driving erratically.

The victim, a woman, was taken away in the ambulance to a nearby hospital. He gathered her purse, umbrella, and other belongings of the street and dealt with the driver and his damaged car. With the 17 year old driver in his back seat, he went to the hospital with the personal affects to give them to the staff. Upon reaching the hospital, the kid was taken inside with him. He opened her purse and checked her ID and..get this...... it was HIS Mother! This kid sitting in the waiting room had just hit the arresting officer's mother with his car and was reading the newspaper! When Grandpa Wes told him what he had done and asked him what happened, he just shrugged his shoulders and said he was late for work! She died a week later in the hospital from her injuries.

Now I don't know what exactly went through Grandpa Wes' mind that day, but he told us years later, had he'd known that was his mother laying on the ground that rainy day, that punk would have NEVER made it to the police station! The guy is my Dad's age and still lives in SE Portland. Somewhere I have articles from around the U.S., but have never found anything online about it, but Grandpa's name was Oren Wesley Olin and Great Grandma's name was Anna M. Olin. Sorry, just another one of my tangents. I like sharing a little history, when I can.


P.S. Yes, fondestly is a real word!

P.S. I kind of like that....fondestly! Hmm....

Sorry about the sad story.....Okay, Back to the original topic.......Here is the replica Delco box I made. I went to Tap Plastics and picked through the scrap bin and I found 6, 8" X 14" pieces of black ABS plastic sheeting. It cost me 4 bucks! Some trial and error and some fabrication, I have a near perfect replica Delco DC-12 box that fits over any Group-24 modern maintenance free or flat-top battery. I used ordinary ABS pipe cement and Acetone for re-shining where I had to sand and file. This may seem a bit extreme to some, but I think it's a better alternative to an inert $300 battery that weighs 35 lbs ! I should take pictures as I fabricate things, but I do have to have some secrets. Besides, I never think of it while I'm doing it, just trying to get the job done. I usually have my Wife around when I'm doing a major restoration to take pictures, but I can't get her to stick around when I'm "tinkering", as she calls it. I haven't been able to figure out why she thinks it's boring....Oh, well! I guess I should be fortunate, at least she's not looking over my shoulder asking questions or kibitzing about what I'm doing.......Anyway, Here's the fruit of my labor:

Exide Group 24-50 Battery



My replica battery!

Inside the box..


The white residue is from rinsing the ABS with acetone, not from battery acid.....



Delco repro Battery from High Perfomance Pontiac Magazine's battery bootcamp website article. Google 1959 Pontiac delco battery and you can learn alot about these batteries and what is correct.




I know mine is not 100% accurate, but keep in mind I'm not finished with it either.

Funny, because the battery I had years ago, did not have the 2SMR53 molded in the case like this picture, but I will put it on, just for fun. Besides, I don't think many will notice when it's in the car anyway. I don't know if it's good or bad I don't have a job (not that I want or need one) but if I did have one, I wouldn't be able to "tinker" and conjure up these neat little projects and it gives me a break from my kitchen remodeling (The cabinet doors are in the background on the table) Not sure if any of you wonder, or even care, but I have moonlighted for years as an actor. I use a pseudonym, which is another of my "secrets", but I have been working on TNT's "Leverage", which is filmed here in Portland. Tim Hutton, is the coolest person I have ever met! He loves the Catalina (the car was not used for filming) and even sat in it. No pics though, cameras and phones are forbidden on set.

Chad.....Great job!!! Couple questions. Did the plastic come with the pebble grain, or did you etch that yourself? Could you use one long piece and bend it around the corners? Can't tell from the pictures, but do the sides sit flush with the flange around the topper? If so, did you have to reinforce that seam?

Don't you just hate it when work interferes with the fun things in life? To paraphrase an old adage "work is the curse of the drinking class.".....John

John- Thanks..I had fun building it! To answer your questions, the ABS sheet does have the pebbled stipling on one side and is smooth on the obverse side. I tried to bend the sheet, but the plastic turns white and has a tendency to crack. Heating doesn't work very well either. It distorts the grain. The best way I came up with was to glue the corners, with an extra strip for reinforcement. I sanded the corners and dressed it up with acetone. Used in moderation, the acetone will shine the plastic. Too much and becomes sticky. There is acetone in the glue, so I use it sparingly!





The second picture shows the seem where the topper and the box meet. The topper is made of ABS as well, so the glue will adhere to it fine. The topper rests on the sides of the box and the strip added to the box. In the 3rd picture, you can see I only put 5 drops of glue, just enough to hold the top on, but will allow me to "score" the glue to remove the top if i have to.



I made the bottom strip out of a reversd piece, scored on the back, lightly bent and chamfered on to top edge to create the beveled edge of the case.


I scored the factory seem on each side, to mimic where they were glued together. The flange on the topper is visible, but it gives the perception of the thickness of the battery and support as well. I still have some detail work to finish up, but for the most part this is what I came up with. It is only a prototype, so I may build a couple more to see if I can make some improvements.




Here you can see the cross-section of the construction. Like a film set, it only has 3 sides, since the back is never seen, I didn't bother to box it in completely. You can also see where I took my die grinder and ground off the hold down flanges on the battery itself. I will figure out something to hold it down. It doesn't have a hold down in the car anyway and has not moved from me driving. So, I'm not too concerned.

Chad.....Two more questions. Is Tap Plastics a national chain or is there an equivalent? I've never heard of them. How did you get the pebble grain smooth where the DELCO word is located? It looks pretty close to original. The battery holddown was a bar across the top on our cars so grinding that away isn't a big deal......John

John- Tap Plastics is only in Oregon, Wa and Ca. Check around at some sign shops in your area. The ABS sheeting is commonly used for sign boards and some hobby shops sell, it too. The stuff is amazingly cheap. Ask if they have a scrap bin and pick through like I did, I just got lucky finding 10 picese the right size. I used 3/32" for the box and 1/16" for the "Delco" cutout and letters. I made a template on my computer and modified the letters before I printed them, but it could easliy be done by eye. I cut the letters out with a pair of scissors and dressed them with a razor knife and sandpaper.




The make the flat part, I cut out the rectangle, using tape as a guide and drilling 4 holes in each corner and cutting the rest out with a knife, then radiused the inside corners with a file. I glued a piece on the inside (the piece with the white residue) smooth side out. I cut another piece to fit inside the rectangle (so it's not so deep, but still recessed). The reason I rinsed with acetone, is to remove the shine so the glue sticks better. Moderation is key here, as too much will soften the plastic. The sheets cut super easy with a razor knife..just score a couple times and snap it off. I used a syringe with a plastic tip to apply the glue. A little bit goes a long way..less clean-up! They might try and sell you adhesive, but the black ABS pipe glue works just fine.

These guys will have what you need:

Proveer Sign & Graphics
10 Runway Drive, Suite G
Levittown, PA 19057
215-945-0700
www.proveer.com

They are not far from you at all.

I was going to add that I put the battery in the car and because it sits in at an angle, the back of it is visible from the front of the car. I think I will box it in completely. This is not a problem, since it gives me a reason to make modifications and improvements!! The glue sets up hard in about three hours allowing work to continue fairly quickly, but the parts will move if disturbed too soon. Not sure if you noticed, but I ground off everything on the outside of the battery to make the box fit better. It may cause some head scratching when turn it in to get a new one, but I'm sure I'm not the first one to do that!!