[corbin]

So, as a follow up, I'll probably buy a box of M8 x 1.25 SS socket set screw bolts, 30mm length. Box of 100 is $30:

http://www.boltdepot.com/product.asp...&cm=67&cd=1553

A box of 100 SS metric nuts for $10

Either traditional lock-washers, or Nord-Lock. Nord-Lock look awesome, but are really expensive. McMaster-Carr:

http://www.mcmaster.com/#nord-lock-washers/=a6c6z9

$7.41/per 5. For 100 that's $148!

I'm going to see if I can find them cheaper. $148 might be too expensive for me at this time.

I'm also first going to double check the screw length; The cell hole is 14mm, so that leaves at least 16mm exposed -- that should be enough for bus bars + bms + nuts, but I need to check my math.

corbin

[dtbaker]

Originally Posted by corbin

So, as a follow up, I'll probably buy a box of M8 x 1.25 SS socket set screw bolts, 30mm length.

yes... I ordered 30mm long, and this gives about an extra 1/4" length of engagement possible compared to stock bolts... should ensure that they can be cranked down all the way to the bottom of the blind holes and have enough threads to prevent pull-out in the soft terminals.

I also though the nord-locks looked great, but way too expensive. A little lock-tite, proper torque, and paint pen on top for inspection ought to do it...

[EVfun]

The price in AUD is almost the same as USD. The Australian dollar is typically worth between 90 and 98 cents US. It is shipping that will hurt, it will cost about $80 to ship 50 interconnects. They are heavy! Still, the total is less than $5 each when you buy enough to do a pack.

[ElectriCar]

So are the TS terminals still steel or something else now? I laughed the other day when I saw someone had a shipment of them arrive with steel terminals and said they already had rust on them.

[EVfun]

My batteries where made in February of this year and the terminals are copper on the negative and aluminum on positive side. The available thread depth is different on the terminals, measure both sides so the bolts don't bottom out before tightening. I think it's the aluminum terminal that is slightly less deep.

[dtbaker]

Originally Posted by ElectriCar

So are the TS terminals still steel or something else now? I laughed the other day when I saw someone had a shipment of them arrive with steel terminals and said they already had rust on them.

I don't think any of the terminals are or were steel... one side is copper, other is aluminum. Hence the need for SS bolts and noalox or other anti-oxidant recommended. Also highly recommended to lightly sand off oxidation, and apply the noalox just before final assy.

[azdeltawye]

Originally Posted by corbin

So, as a follow up, I'll probably buy a box of M8 x 1.25 SS socket set screw bolts, 30mm length. Box of 100 is $30:
...

No need to spend the extra money on socket head set screws. Just get standard stainless steel studs. Install them in the battery terminals by using two nuts tightened against each other. Then once installed in the battery, remove the jam nut and you're done.

The same way you would install a stud in an engine block or motorcycle case...

[ElectriCar]

Just a note, I've taken SS threaded rod, aka all thread, and cut to my desired length on another project. Of course I think it was a 10' piece I bought so screws may be cheaper if that's the minimum you can purchase.

[corbin]

Originally Posted by azdeltawye

No need to spend the extra money on socket head set screws. Just get standard stainless steel studs. Install them in the battery terminals by using two nuts tightened against each other. Then once installed in the battery, remove the jam nut and you're done.

The same way you would install a stud in an engine block or motorcycle case...

Cool -- that looks nice too. I already ordered the set screws...so I'm using those. I like the idea of only having to have one nut -- it reduces the top clearance a little bit, which I need for my front pack.

ElectriCar -- the pos terminals are copper and the neg are aluminum.

corbin

[EVfun]

Originally Posted by corbin

ElectriCar -- the pos terminals are copper and the neg are aluminum.

Other way around, the negative terminals are copper and the positive terminals are aluminum. (the red metal is NOT positive )