[RE-wrenches] Battery interconnect cable length

[Ray Walters]

We once cooked a T105 in an Electric vehicle situation, where the 
terminal was loose and cause the lead around the bolt to melt. They're 
just bolts set in lead. I removed the original bolt, and then drilled 
and tapped into some solid lead to the side of the damage. I was able to 
screw in a 1/4" stud, and make the battery operational again. (Don't go 
too deep, Boom!)
I later sold the battery at a significant discount to a DIY friend. It 
worked fine for him, but you don't want to be setting up a regular 
customer with something that MIckey Mouse.
Seems like the battery manu owes you a battery, I've had over 1000 
batteries installed, and I never had a new post do that (of course I use 
WIndy Dankoff's magic battery butter (vaseline)on everything during 
assembly)

Ray

On 6/7/2011 3:01 AM, bob ellison wrote:
>
> Benn,
>
> What I am talking about is welding the lead cell interconnects between 
> battery cells. Not welding cables to the lead posts, that would be a 
> recipe for disaster.
>
> As far as the galling threaded post, if you try to cut it off it might 
> wiggle enough to break it internally, nothing good down that road. If 
> you cut it off is there enough room to get a nut and lock washer on 
> the remaining stud?
>
> Overall the easy cure is probably replacement, anything else is iffy. 
> But if it works it saves you the cost of a battery.
>
> Bob Ellison
>
> *From:*re-wrenches-bounces at lists.re-wrenches.org 
> [mailto:re-wrenches-bounces at lists.re-wrenches.org] *On Behalf Of *benn 
> kilburn
> *Sent:* Tuesday, June 07, 2011 12:57 AM
> *To:* Wrenches
> *Subject:* [RE-wrenches] Battery interconnect cable length
>
> Thanks for the feedback guys.
>
> Yeah, i suppose that in a single string, cable length is not as 
> important as it would be for the paralleling cables.
>
> Ray, good point that if there are multiple parallel strings, then the 
> series jumpers in one string should be equal length to the series 
> jumpers in each string.  I see the logic in that.
>
> Daryle, 'right-angle lugs', i've seen those.  Good suggestion for 
> difficult connections, thanks.  I'll have to keep a few of those handy 
> for future jobs.
>
> Bob, are you saying that you weld the interconnect cables to the 
> battery posts? and/or use 'plates' to bolt the posts together?  I've 
> seen plates used, but welding the lugs to the posts ....?  ... see 
> next thread.... 'Battery Post Galling'
>
> benn
>
>
> DayStar Renewable Energy Inc.
>
> benn at daystarsolar.ca
>
> 780-906-7807
>
> HAVE A SUNNY DAY
>
>
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