So the 1988 XJ40 I am currently working on has a bad rusted battery tray under the hood.
I was able to carefully use some heat to remove the bolts that hold the tray down to the firewall.

Rusty old battery tray with holes in the bottom of the tray

Once I had the tray out I could carefully measure it and then use my sheet metal brake bend to make a new tray.
I salvaged the two brackets off the old tray and then after bending up the new tray and welding the corners together, I welded the two brackets back onto the new tray.

New battery tray all welded together

I am going to use POR-15 paint to coat the new tray but I am told it only bonds to rusty metal so I have to let the new tray get a light coating of surface rust on it.

 

Nice one Steve. Way to improvise!

 

Good work, so glad my 94 has a battery in the trunk not under the hood ...it stays sparkly clean in there on it's little stand!

Larry

 

Nice work, Steve!

If I recall correctly, POR 15 will bond to sandblasted metal, just not smooth shiny metal. Check the FAQ at their website.

Cheers,

Don