<html><body><span style="font-family:Verdana; color:#000000; font-size:10pt;"><div>Last summer I had to recast a post. A first for me. Some "Battery Expert" installed a bank of Trojans with UT posts using flat cable end terminals, then torqued the b Jesus out of them to try to get them to seat. what happened was they either cracked or totally broke off the terminal at the bolt hole. Borrowed a terminal mold from Babe down at Interstate, and use an old manual soldering iron (the kind you have to heat up with a torch or something) so i had plenty of ummph, but no open flame around the battery. Cleaned and tinned the busted terminal first and then set up the mold. It wasn't pretty, but it worked. db<br></div><div><br></div><div><br>Dan Brown<br>Foxfire Energy Corp.<br>Renewable Energy Systems<br>(802)-483-2564<br><a href="http://www.Foxfire-Energy.com">www.Foxfire-Energy.com</a><br>NABCEP #092907-44</div><div><img id="sigimg0" title="signature image" src="cid:sigimg0@a602c16adab2a469afc50999a6d10071" alt="" border="0"></div><div><br><br></div>
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-------- Original Message --------<br>
Subject: Re: [RE-wrenches] Battery corrosion issue<br>
From: William Miller <<a href="mailto:william@millersolar.com">william@millersolar.com</a>><br>
Date: Thu, January 21, 2016 4:51 pm<br>
To: RE-wrenches <<a href="mailto:re-wrenches@lists.re-wrenches.org">re-wrenches@lists.re-wrenches.org</a>><br>
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</style><div class="WordSection1"><div class="MsoNormal" style="font-size:12pt;"><span style="font-family:"Arial","sans-serif";color:black">Friends:</span></div><div class="MsoNormal" style="font-size:12pt;"><span style="font-family:"Arial","sans-serif";color:black"> </span></div><div class="MsoNormal" style="font-size:12pt;"><span style="font-family:"Arial","sans-serif";color:black">It’s a clearance bolt hole. Drill it out and install a new one.</span></div><div class="MsoNormal" style="font-size:12pt;"><span style="font-family:"Arial","sans-serif";color:black"> </span></div><div class="MsoNormal" style="font-size:12pt;"><span style="font-family:"Arial","sans-serif";color:black">William</span></div><div class="MsoNormal" style="font-size:12pt;"><span style="font-family:"Arial","sans-serif";color:black"> </span></div><div class="MsoNormal" style="font-size:12pt;"><span style="font-family:"Arial","sans-serif";color:black"> </span></div><div class="MsoNormal" style="font-size:12pt;"><span style="font-size:10.0pt;font-family:"Arial","sans-serif";color:black"><img id="Picture_x0020_1" src="cid:image003.jpg@01D15452.D1283660" alt="Gradient Cap_mini" wbeuser="dan@foxfire-energy.com" height="28" width="64"><br>Lic 773985<br><a target="_blank" href="http://www.millersolar.com/"><span style="color:blue">millersolar.com</span></a><br>805-438-5600</span></div><div class="MsoNormal" style="font-size:12pt;"><span style="font-family:"Arial","sans-serif";color:black"> </span></div><div class="MsoNormal" style="font-size:12pt;"><b><span style="font-size:10.0pt;font-family:"Tahoma","sans-serif"">From:</span></b><span style="font-size:10.0pt;font-family:"Tahoma","sans-serif""> RE-wrenches [mailto:<a target="_blank" href="mailto:re-wrenches-bounces@lists.re-wrenches.org">re-wrenches-bounces@lists.re-wrenches.org</a>] <b>On Behalf Of </b>Chris Mason<br><b>Sent:</b> Thursday, January 21, 2016 11:58 AM<br><b>To:</b> RE-wrenches<br><b>Subject:</b> Re: [RE-wrenches] Battery corrosion issue</span></div><div class="MsoNormal" style="font-size:12pt;"> </div><div><div class="MsoNormal" style="font-size:12pt;">There's no need to hit the bolt, just press it out with a pulley puller set for two legs. </div></div><div><div class="MsoNormal" style="font-size:12pt;"> </div><div><div class="MsoNormal" style="font-size:12pt;">On Thu, Jan 21, 2016 at 9:40 AM, Tump <<a href="mailto:tump@swnl.net" target="_blank">tump@swnl.net</a>> wrote:</div><div><div class="MsoNormal" style="font-size:12pt;">I personally would try to soak the offending post in a solution of baking soda or some other corrosion remover for a while and then gently tap the bolt on both sides. Continuing to do this will eventually loosen the bolt.This IS a thru bolt not something that is threaded. certainly one can drill it out using the step approach 1/8 " then 3/16 then 1/4 till you get to 5/16. Gently tapping or drilling you should find this removal easier then you thought. Tump</div><div><div><div class="MsoNormal" style="font-size:12pt;"> </div><div><div><div class="MsoNormal" style="font-size:12pt;">On Jan 20, 2016, at 5:34 PM, Ray Walters wrote:</div></div><div class="MsoNormal" style="font-size:12pt;"><br><br></div><div><div class="MsoNormal" style="font-size:12pt;">The EZ out is for unscrewing a threaded connection, I've spent a bunch of time with those only to have the EZ out break off in there too. Then you've got a real mess of hardened tool steel.<br><br>I would first drill several small 1/8" holes in the lead around the circumference of the bolt. Then, I think tapping or pressing it out is the way. The wheel puller would probably work. You'll end up with an enlarged hole that you can either use a bigger bolt, or washers to deal with. <br><br>I agree some of the hardware that comes with cheaper L 16s, is inferior. I've had plenty of those square heads come off with minimal torque.<br><br></div><divre>R.Ray Walters</pre><pre>CTO, Solarray, Inc</pre><pre>Nabcep Certified PV Installer, </pre><pre>Licensed Master Electrician</pre><pre>Solar Design Engineer</pre><pre><a href="tel:303%20505-8760" target="_blank">303 505-8760</a></pre><div><p class="MsoNormal">On 1/20/2016 3:04 PM, Roy Rakobitsch wrote:</div></div><blockquote style="margin-top:5.0pt;margin-bottom:5.0pt"><div>Yup, id pre-drill and use an ez-out, or use a flaring tool as a small press and drive it out. </div><div>RoyR</div><div><div class="MsoNormal" style="font-size:12pt;">On Jan 20, 2016 3:54 PM, "Kristopher Schmid" <<a href="mailto:solman@legacysolar.com" target="_blank">solman@legacysolar.com</a>> wrote:</div><div>Greetings,</div><div>Do any of you battery gurus have a suggestion for a method of removing a bolt remnant that is corroded into a flag terminal. Both sides snapped off flush with the flag. I was thinking try to drill it out or maybe a small gear pulling tool? I will never again use the non stainless hardware supplied by the manufacturer...</div><div>Picture attached for reference.</div><div>Thanks!</div><div class="MsoNormal" style="font-size:12pt;margin-bottom:12.0pt"><br>_______________________________________________<br>List sponsored by Redwood Alliance<br><br>List Address: <a href="mailto:RE-wrenches@lists.re-wrenches.org" target="_blank">RE-wrenches@lists.re-wrenches.org</a><br><br>Change listserver email address & settings:<br><a href="http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org" target="_blank">http://lists.re-wrenches.org/options.cgi/re-wrenches-re-wrenches.org</a><br><br>List-Archive: <a href="http://www.mail-archive.com/re-wrenches@lists.re-wrenches.org/maillist.html" target="_blank">http://www.mail-archive.com/re-wrenches@lists.re-wrenches.org/maillist.html</a><br><br>List rules & etiquette:<br><a href="http://www.re-wrenches.org/etiquette.htm" 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