[ausev] broken battery terminal

[Chris Robison]

That sounds like a really cool solution, but I wonder about its durability
in an EV application.

The difference between the operating conditions of an electrical
connection being used to start a gas engine, and that of a connection in
an EV traction circuit is extreme. An engine starter may pull a couple
hundred amps for a few seconds, giving little time for heat to build up.

A terminal in an EV, however, is subjected to high current for an extended
period of time. Even lead posts have a tendency to creep over time and use
in an EV, requiring battery clamps to be occasionally re-tightened (or at
least checked). A post made entirely of solder seems like it would be
worse. And the problem isn't inherently self-correcting. As the metal
creeps away from the clamp, the connection resistance goes up, heating
increases, and it creeps away faster.

Now using that same idea with a crucible of molten lead, that might be
just the ticket. Maybe pour it into the clamp with the screw a little
loose, to give you some room to tighten it. Use some aluminum foil as a
wall to prevent the lead from pouring out of the gap...

  --chris




On Mon, May 1, 2006 11:21 am, Mike Delany said:
> Back in my high school hot rod days I melted the terminal off of a battery
> trying to start a 440.  I was broke so I took a lead battery cable
> terminal that I cleaned all of the old crud off of, placed it over the
> melted terminal, and then filled the cavity with solder.  It was hokey but
> it worked.
>
> Mike
>
> Certified heathen and reformed pacifist
>
> http://www.p1800s.com
>