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miketsp - i considered making a sealed battery canister in this way....am still thinking about it....and the fact you built yours "some years ago" tells me this is not a bad idea!
(i was going to put some nimh in some pvc pipe and completely fill the air gaps with silicone)
one thing that concerns me is the potential for it to pop or explode due to (maybe) some gases given of during charging....?
what kind of battery are you using? (SLA/nicd/nimh/Lithium)?
do you have air space inside the canister, or some other way of relieving the pressure?
do you get said pressure at all?
how quickly/slowly do you charge it to avoid the big "boom"?
how often do you use it?
any photos taken during construction?
most curious, as this method completely takes out of the picture the complications around o-rings and glands etc...
one thing that concerns me is the potential for it to pop or explode due to (maybe) some gases given of during charging....?