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Old 07-23-2011, 05:28 PM
gsmith191145 gsmith191145 is offline
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Default How to Repair a battery terminal

I had a loose terminal and melted the terminal end.

I first cleaned and prepped the battery stud. Then I fluxed the stud and applied silicon around the stud to trap the molten lead.



Second I made a mold out of a 4x6 the bottom is shaped to fit the bottom
of the battery post and the top is shaped square.





Now to heat up the lead. I used bullets and skimmed off the garbage.



I then poured the lead into the mold and poured water on my battery just in case of a lead over pour. Do not pour water on molten lead, it will ruin your day. (splatters and burns) I know from casting bullets he he he.



Drill a hole and there you have a new terminal without having to drill and tap into soft lead.

This is way cheaper then letting a battery shop do the exact same thing.

You can get lead from tire weights also. Good luck
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Old 07-24-2011, 07:18 PM
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ElectriCar ElectriCar is offline
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Default Re: How to Repair a battery terminal

Good deal. I don't have lead anymore but had a few meltdowns. I simply drilled and tapped a 5/16 stud into the remains and hoped for the best. Not as good as your repair but it worked without further issues.
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Old 07-24-2011, 09:58 PM
gsmith191145 gsmith191145 is offline
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Default Re: How to Repair a battery terminal

Thank you very much. I hope to be lead free one day when I can afford it. probably within the next six years I gotta save for the batteries and a new charger.
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Old 07-25-2011, 06:01 AM
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poprock1 poprock1 is offline
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Default Re: How to Repair a battery terminal

Hi, good result with the repair. Happened to me many times, I assume because of using contactors only with stepped voltages. I assume that the amps drawn is too much for the posts. What was the reason for your meltdown ?( your battery, not you personally)
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Old 07-25-2011, 02:30 PM
gsmith191145 gsmith191145 is offline
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Default Re: How to Repair a battery terminal

Quote:
Originally Posted by poprock1 View Post
Hi, good result with the repair. Happened to me many times, I assume because of using contactors only with stepped voltages. I assume that the amps drawn is too much for the posts. What was the reason for your meltdown ?( your battery, not you personally)

Loose battery terminal caused my melt down. I usually check them when I water them.
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Old 08-15-2011, 10:49 PM
Snakub Snakub is offline
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Default Re: How to Repair a battery terminal

You should make a youtube video of this. How do you keep the lead from pouring out in between the silicone and the wood?
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Old 08-15-2011, 11:12 PM
gsmith191145 gsmith191145 is offline
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Default Re: How to Repair a battery terminal

Quote:
Originally Posted by Snakub View Post
You should make a youtube video of this. How do you keep the lead from pouring out in between the silicone and the wood?
I made the wooden mold shaped to fit the existing battery post platform. The silicone was for seepage. When in doubt pour water under the mold after the pour. The lead cools down fast anyway.

I will make a video for you tube. I am moving this month and everything is just a mess. But thank you for the reply.
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