Hello Cor, Try gulf cart repair shops. It looks like your batteries do not have the post off set bars that my U.S. Battery has which I bought in 2009.
I had this happen to me with my Trojans with the low profile post that the stud kept pulling out on the off set bars. I temporary use one of those lead post that can screw on to a side terminal battery which you can get from some auto parts store. Best to use a post with a hexagon base so you can use a socket on it. Clean off the remaining post with a speed bit which makes a flat smooth surface and a small V hole. I had to grind down the larger V pilot bit to on that was 1/8 in diameter. Measure the diameter of the temporary post stud and drill a hole into the remain post in the battery with a drill bit that is 1/8 to 3/16 inch smaller than the stud. For other metals, we use 1/8 inch smaller and for soft metals as lead, use 3/16 inch bit. Tap threads in the hole with the same size as the temporary post stud threads. First screw the post in to see how it fits, then remove it, clean the base where it will contact the battery post and apply a coating of cold solder compound which you can get at any of the hardware stores. Tighten the post to about 40 inch lbs. Let set for 24 hours. Installing a battery link to this, first clean the new post and battery clamp with a battery cleaner brush. Torque the battery clamp to at least 65 inch lbs. It is very common when initialing tonguing these types of battery clamps to any battery post, the scratch marks cause by cleaning the battery clamp and post, does not mate completely. I then drive the EV for about 5 miles and torque the connection again. You will find that this type of connection could lose up to 5 in.lbs. Check all you battery torque readings and adjust as required. After two initial torques, I than check all the battery clamps in a week, than in a month, and every three months. The battery lead cleaning scratches melt back which is known as SHRINK BACK. Roland ----- Original Message ----- From: "Cor van de Water" <[email protected]> To: "Electric Vehicle Discussion List" <[email protected]> Sent: Thursday, March 28, 2013 2:46 PM Subject: Re: [EVDL] Re-casting battery post that melted away? > BTW, > I just now checked and found that the damaged battery is > still at 6.27V so no immediate internal damage other than > the missing post and a small hole melted in the top of the > cell - which will obviously need to get patched also... > > Cor van de Water > Chief Scientist > Proxim Wireless Corporation http://www.proxim.com > Email: [email protected] Private: http://www.cvandewater.info > Skype: cor_van_de_water Tel: +1 408 383 7626 > > > -----Original Message----- > From: [email protected] [mailto:[email protected]] On > Behalf Of Cor van de Water > Sent: Thursday, March 28, 2013 1:18 PM > To: Electric Vehicle Discussion List > Subject: [EVDL] Re-casting battery post that melted away? > > Yesterday on my way from work I lost all motive power in my EV truck, > > after an initial warning when I just entered the freeway of a short > > power loss but since I was eager to get where I was going to and did > > not want to pull off the freeway, I kept going. Frankly - I hardly > > recognised the brief loss of power as a warning that something was > > amiss, but I would soon found out that the warning was serious > > and I should have taken action right away. > > Few more miles down the road I was about to go up an overpass > > where freeways intersect and I lost all power. Lights still worked > > so 12V was still available but no power from the pack. > > I was still hopefull that my 200A breaker finally tripped on my > > sustained 300A draws while I coasted to the side of the road, > > but looking under the hood I saw the breaker still in ON position. > > I turned it off anyway and back on - maybe it would reset something? > > But no - still no power, even the display in the car did not light. > > Hmmm - that meant that there was actually no power from the pack, > > not some controller error. > > Grabbing the multimeter I checked and indeed - no voltage from > > the pack. The front 4 batteries were fine and delivered 6.2V each > > so I undid the bolts for the bed and lifted it up (after walking back > > 50 yards to set out a warning cone on the edge of the shoulder > > since my hazard lights are not visible much with the bed lifted). > > > > In the middle of the pack I spotted a yellow blur under a clamp > > that was desperately holding onto air.... Where did the post go? > > As you can see on this picture: > > http://evalbum.com/popupimg.php?24271 > > the post melted and the lead had run onto the next battery, > > covering the entire width of that battery with a strip of lead. > > More pics on the EValbum page: http://evalbum.com/4259 > > > > Luckily with a wrench I could undo the damaged interconnect > > (the clamp on the other side, on the next battery) and move > > the clamp from the other post of the damaged battery to the > > now free clamp on the next battery, removing the bad one > > from the string and continuing on my way on a 114V pack. > > > > Anyone a recommendation where I can best have a post re-cast? > > I am in San Francisco South Bay area (AKA silicon valley). > > > > I have an alternative for the damaged battery, since the truck is > > setup up with 22 identical batteries - 2 are used as aux battery > > and serve as spares, so I can swap one of those into the pack > > and only need to connect to the damaged battery for the aux > > load, which is typical no more than 20A instead of the 300A that > > the pack will see. Still I prefer to have a post again on this battery. > > > > Regards, > > Cor van de Water > Chief Scientist > Proxim Wireless Corporation http://www.proxim.com > <http://www.proxim.com> > Email: [email protected] Private: http://www.cvandewater.info > <http://www.cvandewater.infom> > Skype: cor_van_de_water Tel: +1 408 383 7626 > > > > -------------- next part -------------- > An HTML attachment was scrubbed... > URL: > <http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20130328/5637 > baa0/attachment.htm> > _______________________________________________ > UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub > http://lists.evdl.org/listinfo.cgi/ev-evdl.org > For EV drag racing discussion, please use NEDRA > (http://groups.yahoo.com/group/NEDRA) > > _______________________________________________ > UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub > http://lists.evdl.org/listinfo.cgi/ev-evdl.org > For EV drag racing discussion, please use NEDRA > (http://groups.yahoo.com/group/NEDRA) > > _______________________________________________ UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub http://lists.evdl.org/listinfo.cgi/ev-evdl.org For EV drag racing discussion, please use NEDRA (http://groups.yahoo.com/group/NEDRA)
