Nisei Team
Joined: 25 Apr 2005
Posts: 115
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First, I’d just like to say we are very proud to release out newest 2010 Genesis CNC Billet Tray Assembly! As with everything we do we try to elevate the standards of the industry by producing the best products and quality possible!
Before we begin, we’ve deliberately did not placed the other brand name plate below to avoid name bashing. We’ll simply refer to them as Brand A & B. Also, I’d like to apologize for the crude photos take with my standard pocket canon.
The purpose of this is to allow you to get some good insight without having to experience buyer remorse. As they say a photo is worth a 1000 words. I’ll keep the photo descriptions brief and direct as possible for you.
Kit break down of components.
View is of the bottom side of the tray base:
Damage above caused to “Brand A” is due to a poor design. There should be a cut out where contact occurred between the chassis and base of the tray (mounting point). As will be presented in the photos below.
Close up view of damaged area:
As you can see from our mounting bracket we’ve removed the section where contact can occur with chassis.
Like many companies “Brand A” utilizes aluminum sheet metal, which is typically cut with a band saw, or laser cut. Then bent to shape. To the right we have our CNC base which starts out as a 1.125” plate and is CNC machined with precision for the perfect fit.
Quick side note, you can see the machine lines inside of the tray assembly indicating the number of passes per layer. To get to this depth it required 3 or 4 passes.
Above Brand A looks to have modified J-Hook’s with wing nuts as battery posts. It’s difficult to see based on the photo but, during the welding process there is an area where the weld has actually melted the bolt down.
Again, our post require several machines to produce it due to the complex round, hexagon, and taper design.
Below I tried to take a photo showing the melted bolt. My pocket camera could not get a clear picture to show the damage. Sorry.
When working with sheet metal whether cutting material with a press break, band saw, laser cutting. Usually requires clean up such as sanding to remove flash, rough edges, bur’s, etc. On this particular unit Brand A sold it as a finished item. A customer was nice enough to give us this after upgrading to one of our Billet Genesis Trays.
A difference of CNC and say Laser cutting or using a band saw is the lack of depth that can be created by those other methods. Which can be seen above.
This was just to show you guys who need to know material thickness.
Brand B has a completely different design. Using a rear mount instead of a front mount. Again, made from sheet aluminum.
Just want to mention tolerances for a sec. When making sheet metal trays, you have to allow yourself more tolerance. Mainly because after your basic shape is cut out you still have to bend it. If you do not calculate for the amount of material difference : grade of material, degree of bend, spring back, etc. The likelihood of it not fitting correctly is high. The tighter the tolerance, the more likely it’s not going to fit!
Again this is the basic reason sheet product carries a sloppy fit.
With CNC you can have a precise tolerance/tight fit. Accuracy is not a problem because there is 1 basic process. Removing material, no bend, twisting going on or anything to compensate for. Quality is bar none and finish is exceptional : radius corners, beveled edges, depth, contours, tapers, etc. Can all be done during this machining process.
This next photo will show you 2 things:
1) Why an oversized hole is required in the first place.
2) Where those threads were created.
Point 1 – Oversized hole required because sheet metal. Even with the oversized hole there was still fitment problems. It is a difficult process to master.
Point 2 – The threads were actually created because the bolt was a forced fit. The alignment problems put stress on the tie down bracket and we all know steel is stronger than aluminum. Steel bolt created thread without having to use a tap.
This was probably cause due to a bad design which I’ll be able to explain/show you a few more photos down.
Here are some of the finer qualities created by CNC I’m sure get overlooked. Multiple depths, shape, precise fitment, smooth radius, beautiful finish!
Precision/tight tolerance allowing for 2 pcs meet together without overhang.
Component breakdown.
Here is the part where I will be able to explain the bad design and possible explain why someone would use pliers to assembly Brand B’s tray.
That bolt on the bottom side of the base is used to hold the post in position.
Design flaws:
With the bolt being on the bottom of the tray causes problems:
1) It’s not flush to tray, which causes the tray to lift at an angle.
2) This may compromise the mounting hole location.
3) Requires larger oversized holes for mounting alignment.
Note : Had the material been thicker than 1/8" sheet. It would have been possible to counter sink the hole and allow tray to sit flush.
Rear mount design:
1) Installation : Usually people install the tray before installing the battery. With this design you are pretty much forced to hold the post with pliers since there is a bolt on top and bottom of the unit.
2) If you attempted to install the battery into the tray first in hopes you would not scratch your post. Then now you run into the problem of trying to bolt it down to the chassis with a battery in the tray.
Based on the bolt head markings on the base of the tray. You can clearly see even with oversized holes the alignment is still not centered.
Again for you guys who like to know thickness. Here is the base of the tray or main tray assembly .125” or 1/8” thick.
Now, here is an example of the manufacturer claiming that it fits with a stock air box. Turned out the tray was modified by our customer to create the clearance required to fit with the stock air box. Now, it is possible that he/we received a bad piece… which would explain all the oversized holes, holes not aligning centered, and fitment issues but, knowing what we know. It has more to do with the type of material and process to make these trays. The probability of running into complications is very high!
This is exactly why we don’t produce our units with sheet metal. Higher Quality materials and Higher Quality CNC machine processes = Higher Quality Products!
Last section! The batteries!
Now, I know a lot of people and companies will not give it to you straight. This is what I find disappointing in the industry. What I’m going to do is to make sure you guy's whom are Nisei customers or potential customers know the facts.
We offer 2 different batteries from the same manufacture :
1) Enersys Genesis – Yes, this is why our tray is called Genesis. It was specifically designed for the Evo and Genesis combonation.
2) Enersys Odyssey PC680 – Simply because some of you prefer this battery which has about 20 more CCA’s than the Genesis.
I love this next photo, because I really want you guys to understand this section and know more than the guy at the other company who just answers the phone and try’s to take your money. BIG MISCONCEPTION!!! PC680 does NOT have 680CCA’s. Nor does the BRAILLE MINI! ( We deal with the Manufacturer of Braille. Braille is NOT a battery manufacturer)
As clearly indicated on the battery itself 220 CCA’s. I know a lot of you weren’t able to see this since other companies claimed to produce their own batteries or covered it up with their own decals. Not to mention those other guys told you that it has 680 CCA's. You've been lied to!
PHCA = NOTHING!!! It is not an official rating and carries no value other than marketing. It is not a standard in the battery world of testing. Will be explained shortly.
Next which battery is better? Odyssey or Genesis:
1) Technically the PC680 has a little more power.
2) It’s orange and a lot people don’t like that.
3) From day 1 we’ve used the Genesis with no problems! In fact our original prototype vehicle is still driving around with the 1st Genesis we ever purchased. 6 years later!
4) They are both made by Enersys.
5) Both backed with the same warranty.
6) PC680 is a bit more expensive.
My preference is the Genesis simply because we’ve sold more Genesis than Odyssey’s and it’s solid black!
Here are 2 keys that really matter for those who don’t want to learn about batteries. Simple explanation the more the better:
1) CCA – The official standard where battery is tested for 30 seconds of cranking in 0* F.
2) Reserve Capacity – Capability of using “x” amps for a duration of about 25 mins until dying.
PHCA - is HCA = Hot Cracking Amps (test consisting of 80*F weather cranking for 30 second duration and taking measurement) test for a short burst and taking the measurement after 3-5 seconds.
Mini batteries are limited with these 2 areas due to physical limitations!
To know if a mini battery is right for you :
1) Less you drive (distance per start up) - You should consider relocation.
2) Do you sit in your car with a with : Lap top plugged in, while having the lights on, with the 1000 watt system on with the engine off? If so, then it’s not for you.
3) Do you leave your car parked outside in 0*F without driving it for a week? Again probably not for you.
4) If you commute in your car everyday and drive 7 miles per start up then I’d say you should not have a problem.
5) If you live in cold climate and garage your vehicle then it should be fine.
6) If you driver your car on the weekend only and get a quick disconnect for the battery you should be fine.
7) If you drive occasionally and get a trickle charger, you should be fine.
8) If you have a EMS or MoTec and you driver your car once a week, for 2 miles per start up. Then this is not for you.
Matte Black (limited production)
Nisei Black
Nisei Black & Matte Black side by side.
Nisei Blue
Nisei Red
Note: Polished is available just not featured here today.
Genesis Tray Kit |
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