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Old 07-18-2019, 04:52 PM   #1
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Question Naval Jelly for Battery Compartment Rust?

Hello all,

I'm just starting a project to replace all three batteries in our 2003 Itasca Sunrise 36M, and I want to take care of some rust in the battery compartment. When I was in the Coast Guard we used wire brushes (and needle guns) and copious amounts of Naval Jelly to combat rust. I have some Naval Jelly but I can't help but wonder if there's something better after forty years, so if anyone has any better ideas, please let me know. Once the rust is taken care of, I plan to paint the compartment with two coats of Rust-Oleum, unless someone knows of a better product - please let me know.

I'll post pictures as this project progresses under this thread.

Anyway, the compartment measures ~29"x15"x12.5" and the opening under the step measures 13.75"x26.5".

The original chassis battery was a Motocraft BXT-65-750 (BCI 65, 750 CCA, ~12"x7.5"x8"). The existing chassis battery (AutoCraft Gold 65-2, BCI 65, 850 CCA, ~9.75"x7"x7.75") will be replaced by an Optima Yellow D31A (BCI 31, 900 CCA, ~13"x6.75"x9.5").

The two house batteries (Autocraft 27DC-2 Marine Battery, BCI 27, 600 CCA, ~9.75"x7"x7.75") will be replaced by two Optima Blue D31Ms (BCI 31, 900 CCA, C20 75 AH, ~13"x6.75"x9.5").
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Old 07-18-2019, 05:35 PM   #2
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There are newer options around now. I don't have any brand names at hand, but look for products called "rust converters". They chemically combine with rust, rendering it inert, and supposedly using it to form a primer. We used such things when I was a wastewater plant operator many moons ago.
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Old 07-19-2019, 05:33 AM   #3
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I use this stuff, it comes in spray, and brush on. Works great and available at auto parts stores.

Loctite® Extend Rust Neutralizer Spray
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Old 07-19-2019, 09:10 PM   #4
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https://www.por15.com/

Here;s a complete kit

https://www.amazon.com/POR-15-40909-...-1-spons&psc=1
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Old 07-20-2019, 07:47 AM   #5
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I used Naval Jelly on my previous MH. Worked well. Then I found the Rust-Oleum rust desolver and used it, along with their paint for protection. The Jelly I used in the battery compartment, the Rust-Oleum I used in all the other bays,

Winnebago did a horrible job on my 2008 with their dipping method. I could not measure how many thousandths of an inch thick it was. Not only that, there was no primer under their paint, After using the products to remove rust I used the Rust-Oleum primers and paints. Held up well.
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Old 07-24-2019, 05:45 PM   #6
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As an RV reconditioner, renovator and repair guy, I clean the battery area as best you can, water, baking soda, some wire brushing. When dry, hit it with the Rust Reformer previously mentioned. When dry, rubber Undercoating. Lasts pretty well.
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Old 07-24-2019, 08:35 PM   #7
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POR-15 is amazing stuff...but you need to start with a clean surface, use the primer and top coat. I used it in areas around the bay storage. It's also recommended for windshield frame protection (when you replace a windshield...rust in the windshield steel framework is common for Winnebago products).
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Old 07-25-2019, 05:57 AM   #8
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Baking soda solution to neutralize acid. Naval Jelly is an inexpensive option that works. Rustoleum is a fine solution. We’ve done it in all of our rusted areas of our 2002 Itasca Horizon, and there were plenty.

On that note, I think I read somewhere that Freightliner did not recommend painting of the frame, yet ours was painted. Water has gotten between the paint and metal, causing extensive rust. Whenever I am underneath, I take my scraper with me and remove a little more peeling paint.
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Old 07-25-2019, 10:04 AM   #9
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Battery Box

I just re-did my box in my 2005 Aspect 23D. Baking soda and water, wire brush, rust converter and rustoleum paint. While you have the batteries out, make sure that you use some "metal" (not cloth) screen on any of the ventilation openings in the box. It will keep the critters out of there!


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Old 07-27-2019, 12:27 PM   #10
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I used a product called Krud Kutter, really works well, and fast on rust buildup.

Followed that up with some Rust-Oleum primer. After that, I used the spray on Flex-Seal, you know the stuff, advertised on TV, figure even acid won't penetrate that rubber coating.
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Old 08-12-2019, 05:23 PM   #11
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Ospho works well too. Available wherever paints are sold. I've even seen it at sherwin williams stores. Used to use it on ships. It's a rust converter.
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Old 09-16-2019, 08:29 AM   #12
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Thanks for the input. This "little" project ended up being much more work than I anticipated. I completely wire brushed and neutralized the existing rust with baking soda and then treated with Ospho 605 Metal Treatment. I'm pleased with the results.

Then I decided I also needed to fabricate a better battery hold-down, and I did that with a 1.25" aluminum bar with four hols which I covered with a piece of heat-shrink tubing, and four long carriage bolts.

I also added a six-position fuse block for future expansion and a 500 Amp shunt for the "Pfangpusun" branded BMV-700 battery monitoring system, which is only 69 USD on eBay (very, very similar to the "Victron" BMV-700).

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Old 09-16-2019, 02:51 PM   #13
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That's a nice battery compartment. Good on you! Makes me want to do mine too. Maybe next spring. Too much going on until then. Bet it makes you feel good when you open it up.
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