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Discussion Starter #1
Two hours ago today a low profile post on one of fifteen Trojan T-875s
in my Ghia blew off the case. No melting or other damage to the case
or the remaining post and cable. Just a pop, some smoke and a dead car
rolling through an intersection. It was a quick fix to bypass the
battery and get home (thanks Roland, I had wrenches in the car).
Nothing was hot or loose, just broken. My guess is that I may have
cracked a post while torquing the nuts down ( and no Roland, I did not
use a torque wrench). The battery in question otherwise seems fine.
Are there any other potential causes that I should be concerned about?
Guesses or concerns? Thank you all in advance.

Bruce

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70 Posts
Discussion Starter #2
a) If it gradually got loose b/c of "lead creep,"
that would explain it.
b) If you were boogieing up a hill at 45, and shifted
into a higher gear, that would explain it.
Been there (b), done that.
peace,

--- Bruce Williford <[email protected]> wrote:

> Two hours ago today a low profile post on one of
> fifteen Trojan T-875s
> in my Ghia blew off the case. No melting or other
> damage to the case
> or the remaining post and cable. Just a pop, some
> smoke and a dead car
> rolling through an intersection. It was a quick fix
> to bypass the
> battery and get home (thanks Roland, I had wrenches
> in the car).
> Nothing was hot or loose, just broken. My guess is
> that I may have
> cracked a post while torquing the nuts down ( and no
> Roland, I did not
> use a torque wrench). The battery in question
> otherwise seems fine.
> Are there any other potential causes that I should
> be concerned about?
> Guesses or concerns? Thank you all in advance.
>
> Bruce
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>


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Discussion Starter #3
Hello Bruce,

That's that problem with these low profile post. The terminals stud head is
only about 1/8 inch below the surface of the pad. According to Trojan, they
are design to be torque down at 95 to 105 inch lbs, but the batteries I had,
they seem to be pulling out at 75 inch lbs.

This cause them to loosen up. I modified my battery connections by clamping
a narrow gold plate battery clamp which had to be all positive size around
the battery pad. I had to spread the battery clamp a little wider with a
battery clamp pliers and install a 1/4 inch longer stainless steel bolt in
the battery clamp.

I also had to use the top battery stud with a washer and a nut to put a
little downward pressure on the battery clamp, so it would not slip off
during the initial installation. I made a lead washer to fill in the top of
the clamp by using pure 100% lead wire than you can get from a fish and
tackle store. I find that the battery clamp provided a pressure around the
head of the stud, so now it could be torque at 75 inch lbs with out pulling
out.

This repair type of battery clamp can be purchase from www.wirthco.com. It
comes with a thru bolt and wing nut, but use a stainless steel washer and
nut to connect you link wire terminal to it. The positive clamps are
#22206. I had a minimum order to make, so I order 70 of these positives for
10 order and I then order 40 negatives #22207 for future install for a
standard post on my next battery pack.

These cost me about $1.75 each at the time, could be way up over $2.00 now.

I had these clamps on for about five years now with no additional
re-torqing. Another advantage I found with these gold plated clamps, that it
provide a bi-connection, which now there is no corrosion between a standard
plated battery terminal and the lead.

If you look at the mating surfaces of the plated cable terminals to the lead
of the post, you will notice there is some type of depilating at these
contact surfaces, that may cause shrink back and a high resistance at this
point.

Roland


----- Original Message -----
From: "Bruce Williford" <[email protected]>
To: <[email protected]>
Sent: Thursday, August 23, 2007 8:47 PM
Subject: [EVDL] blowed-up battery post


> Two hours ago today a low profile post on one of fifteen Trojan T-875s
> in my Ghia blew off the case. No melting or other damage to the case
> or the remaining post and cable. Just a pop, some smoke and a dead car
> rolling through an intersection. It was a quick fix to bypass the
> battery and get home (thanks Roland, I had wrenches in the car).
> Nothing was hot or loose, just broken. My guess is that I may have
> cracked a post while torturing the nuts down ( and no Roland, I did not
> use a torque wrench). The battery in question otherwise seems fine.
> Are there any other potential causes that I should be concerned about?
> Guesses or concerns? Thank you all in advance.
>
> Bruce
>
> _______________________________________________
> For subscription options, see
> http://lists.sjsu.edu/mailman/listinfo/ev
>

_______________________________________________
For subscription options, see
http://lists.sjsu.edu/mailman/listinfo/ev
 
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