[ausev] broken battery terminal

[Ellison, Tom F.]

As another hot rodder following along, perhaps a drilling and tapping
approach could work if there is lead post enough to work with, both to
hold a clamping bolt thread, and to form the new post that is bolted on.
It's a long shot.  If so, a little JB weld might help hold the clamping
bolt threads in place.  I don't know if the remaining battery post in
question has enough material to allow this threading approach, but as
soft as lead is some JB weld might compensate for it not being possible
to torque a clamping bolt.  It would be important to establish a really
good clamping surface for moving those electrons across, since use of JB
Weld would probably mean no conductivity through the bolt. 

Tom

-----Original Message-----
From: ausev-bounces at austinev.org [mailto:ausev-bounces at austinev.org] On
Behalf Of Chris Robison
Sent: Monday, May 01, 2006 12:36 PM
To: AustinEV announcements list
Subject: Re: [ausev] broken battery terminal

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
>


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