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Dipstick, I also had a metal BB that rusted through. So I got one of the newer plastic boxes a couple years ago, and all is well.
I got the data stickers from either Bigmike or on e-bay.
One of the jobs I hate to do every 2 to 3 years.....front axle dust boots and clamps. If someone made dust boots that would last several years, he would be a Millionaire. 
Tracer thanks for the post and pic! I just ordered a plastic battery box myself. It should have it pretty soon. I guess you drilled the plastic box and repositioned the handles?
True about the boots. I've actually gotten so good at it, that I almost don't mind doing it anymore. The first time I did it, I got these cheap Chinese made boots and their I.D. was too small. Every time I tried to stretch them over the grooves they popped off before I could get the clamps on. I worked on them all day without success. I used every foul word I knew more than once. The solution was to have my son "Soldier B" hold one half on while I did the other. With "Soldier B" assisting it went very quickly.View attachment 830117 One of the jobs I hate to do every 2 to 3 years.....front axle dust boots and clamps. If someone made dust boots that would last several years, he would be a Millionaire.
I've replaced the solenoid twice myself. Try this first. Give the solenoid a few light raps with a hammer. Sometimes the plunger gets stuck. I once got stuck 20 miles from home on a snowy, cold day due to my solenoid. The hammer trick got me started. I ordered a new one when I got home. I always carry tools and wire when I go for a drive.
Dipstick, the BB came as pictured. I had to drill two holes in the BB support rails so the handles could lock down as pictured. Then the diaper pins lock the handles. When installed, check the backside of the BB to make sure all the cables are routed properly. (not chaffing)
Dipstick, I'll be 67 in a couple months. My arthritis always reminds me how much I dislike this job. What I dislike even more is knowing the job needs to be done, and not doing anything about it. So I have to get with it like it or not. We have the big MVCC gathering the last week of April 2021, and the truck has to be right. It's 380mi each way for me and my Navigator. The only advice I can give is don't get old.
Thanks again Tracer! I don't know if I have the tabs with holes that the pins/handles drop into on my truck. I think that my cross-piece is rusted on Brutus too. I may have to cut it out and replace it using my much admired stick and blob welding technique. I certainly know what you mean about cable chaffing when you push the box all the way in.
Dipstick, I had to drill the holes in the support rails. I haven't modified the plastic BB in any way.
Okay Tracer thanks. I'll keep you informed once I get the new box delivered and commence repair operations!
Please do.
By the way Tracer, I just turned 68 on March 15th. I'm pretty zippy for my age though and I can still work really hard. It's the soreness afterwards that reminds me I'm not 30 anymore. The soreness doesn't last long. I guess it's more like tired muscles really.
Sounds like a incorrectly wired switch to me. I'd go with the Stock lever switch unit myself. I changed mine years ago. They're a bit of a pain to install, but worth it. As far as uphill/downhill Deuces are sometimes referred to as Dragonflies. They drag uphill and fly downhill.
I think you are correct about the solenoid. It sounds to me like the plunger inside is stuck. It happened to me. I didn't even get a click from the solenoid, so I thought the starter switch could be bad. So I ran a 12 ga. jumper wire from the battery to the solenoid and he still wouldn't start. I rapped the solenoid body with a hammer and touched the jumper wire to the solenoid again. Brutus started right up. One more thing to note, the solenoid plunger is usually spring return, so if your battery voltage is low the coil won't develop enough magnetism to overcome the spring and make the contacts.
Dipstick, I don't do to bad unless I have to lay down on the concrete and work with my hands over my head. Like installing front axle dust boots. But I got both front wheels done, one yesterday, and the other today. It used to be about a 4 hour job several years ago. Now I know why so many of our Senior MVCC members have jeeps.
Ditto on working on your back with your arms and hands above you. I was working on another truck of mine the other day while on my back swinging a 5 pound hammer to drive out a spring suspension pin. It was hard to swing the hammer with any force, but I got it done. Do you have an external air cleaner canister like an old 5 ton on your Deuce's fender? I always thought they looked super cool. Yeah, if I had a brain I'd own a jeep too. But I don't. I wish the damned rain would stop so I could get some work done around here. Glad to hear you got your boots on.
View attachment 830117 One of the jobs I hate to do every 2 to 3 years.....front axle dust boots and clamps. If someone made dust boots that would last several years, he would be a Millionaire.
I had a similar experience when I pulled my fronts apart to change the inner oil seals. Someone left two 1/2 " steel nuts inside the driver's side brake drum. The nuts broke chunks out of the brake linings and grooved the entire I.D. of the drum. I went for new shoes on both sides and a new brake drum on the driver's side. I had been driving Brutus for seven years by this time and never felt or heard a thing!
Good idea Dipstick. If there is one thing I can't stand, it's butchered hardware. When I see an MV that has had a lot of hard work and money put in, and then the corners of the fasteners are rounded off, rusted, and have chisel marks. It just down grades all the money and effort that was put into the vehicle.
