There are several methods to repair a battery post. A quick temporary one is to use a post that screws on to the side terminals of a battery. These are use by battery shops to charge this side terminal batteries or you can get them from some auto parts store.
Prepare the surface of the damage post by milling it flat with a 1 inch speed bit. This will give a center starter hole. These side terminals post adapters come with a 5/15 threaded stud it in and a hex shoulder. Drill a hole in the battery post area with a 1/8 inch drill bit only the length of the stud. This will be the pilot hole for the speed bit. Then drill this hole with a 1/4 drill bit for a 5/16 inch NC bolt tap. Tap this hole with a 5/16 inch NC bolt die tap with plug tap. Do not use a taper tap which will not allow you to tap all the way to the bottom of the hole. Brush the base of these post adapter and screw it on tight to about 10 inch lbs or less then one foot lb. You can later seal the two matting surfaces with a lead wire, that can be melted using a shallow post mold made out of a 1 inch diameter black steel pipe which is cut 1/4 to 3/8 inch long. I get the 100% pure lead wire that comes on spools from a fish and tackle shop they use for lead weights. This places a small raise shoulder at the bottom of the post. Because this steel pipe is straight and not taper like a post mode is, it will stay on. First clean this pipe to a bright clean surface and apply some solder flux to the surfaces. Tinned this with some 50/50 solder before installing it on to the temporary post. Use a small pencil thin flame torch tip. You can actual get lead burning tips from Victor for lead working that have a long thin flame. It is best to have the battery discharge to about 50% SOC and let it set with the caps off for about 24 hours. Before you start the flame work, Place several sheets of wet paper towels on top of the battery and around your work area. The cover the wet paper towels with a wet thick wool cloth. Keep a spray bottle next to you to re-wet the surfaces if required. The other method I use is use battery post molds than you can purchase from a battery shop. This are higher molds which will required the long thin battery melting tip. The Victor 00 size will work, but keep the flame as small as possible. You will need to put down pressure on these post modes while you are melting the lead, because the lead may float these post mode up. Roland ----- Original Message ----- From: VA7DVR via EV<mailto:ev@lists.evdl.org> To: ev@lists.evdl.org<mailto:ev@lists.evdl.org> Sent: Friday, December 04, 2015 12:44 PM Subject: [EVDL] Melted Battery Post repair I spent a bit of time researching this topic and finally stumbled on to the Forklift Industry practices with regards to battery pack construction. I think I/we have a lot to learn from this group. The video link is one I created using the techniques I picked up from the forklift folks. Enjoy ------ WARNING ------ do not attempt this without adult supervision ;) i.e. do not try this at home unless you are prepared to take on all the full responsibility for yours and everyone else around you's safety. https://youtu.be/ndnJnfXkt9c<https://youtu.be/ndnJnfXkt9c> Happy Trukin _______________________________________________ UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub<http://www.evdl.org/help/index.html#usub> http://lists.evdl.org/listinfo.cgi/ev-evdl.org<http://lists.evdl.org/listinfo.cgi/ev-evdl.org> Read EVAngel's EV News at http://evdl.org/evln/<http://evdl.org/evln/> Please discuss EV drag racing at NEDRA (http://groups.yahoo.com/group/NEDRA<http://groups.yahoo.com/group/NEDRA>) -------------- next part -------------- An HTML attachment was scrubbed... URL: <http://lists.evdl.org/private.cgi/ev-evdl.org/attachments/20151204/80276df0/attachment.htm> _______________________________________________ UNSUBSCRIBE: http://www.evdl.org/help/index.html#usub http://lists.evdl.org/listinfo.cgi/ev-evdl.org Read EVAngel's EV News at http://evdl.org/evln/ Please discuss EV drag racing at NEDRA (http://groups.yahoo.com/group/NEDRA)
