DIY simple aluminum battery trays

Flat bar 2" aluminum

High Density Foam Pads (the packing foam from Castle or Turnigy ESC's work great!!)

Double-Sided Tape
Cutting Tool (saw, rotary, grinder)

Countersink drill bit
Torch (propane or map)
Bench Vise
Hammer
Heat resistant Gloves (welding)

Measure battery to be used and add 2-3 inches of length and cut the aluminum.

Place battery in center of cut aluminum bar and mark bar approximately 1/4 - 1/2 inch on either side of the battery.

Now heavily mark the bar again 1/4 inch further away from the battery than the first marks.

Place battery aside and clamp the bar in the vise such that the heavy mark is at the top of the vise jaws.

Steadily heat aluminum at the point where the jaws are clamped until the aluminum becomes extremely reflective.

While still hot, bend the aluminum bar to a right angle while using the hammer to create a tighter angled radius. ***do not bend too quickly, the aluminum may crack***

Mount using existing holes in the chassis if possible, if not drill holes in the chassis countersinking the holes to maintain a smooth underbody. 

Use a piece of scrap paper to mock up the location of the holes needed in the battery tray.

Drill out the holes in the battery tray and secure with appropriate screws and lock-nuts.

Cut foam pads to appropriate size and attach with double sided tape.

Enjoy your new secure and lightweight battery tray :-)