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Unread 06-11-2015, 07:31 AM   #1
Not Yet Wild
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Default Battery terminal post broke off

While driving my car, earlier in the week, it suddenly lost all power and died. When I lifted up the seat, I found that a battery terminal post had completely broken off. This is a 48 volt cart with a Plum quick motor upgrade. Any suggestions on how to prevent this is the future or is this just bad luck? I did check to make sure that all of the connections are tight.

Thanks!
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Unread 06-11-2015, 08:05 AM   #2
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Default Re: Battery terminal post broke off

Never seen that before. They may have been so tight it pulled loose. You don't have to crank down on the nut, just snug. I'm not saying you over did it, just that it can happen. Looks like that could be melted back on, but I don't think I would try it with a live battery. The drill and tap repair would be best. I would remove battery from cart even before doing that. Too big a chance to blow something up with all the other batteries in there.
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Unread 06-11-2015, 09:12 AM   #3
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Default Re: Battery terminal post broke off

Default Re: Drill and tap melted battery terminal?
I use an 11/64" Drill bit and drill one inch deep. Tap it with a 5/16 tap and put a bolt in it. 5/16" x 1"
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This is a quote from a post where tahoedog71 explained how to fix.
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Unread 06-11-2015, 09:29 AM   #4
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Default Re: Battery terminal post broke off

Above quote was from TahoedawgZ71. Do a search and a bunch of stuff comes up.
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Unread 06-11-2015, 09:51 AM   #5
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Default Re: Battery terminal post broke off

That was a typo, David corrected the size on the next post to 17/64".

Drill and tap melted battery terminal?
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Unread 06-11-2015, 10:01 AM   #6
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Default Re: Battery terminal post broke off

Quote:
Originally Posted by Sergio View Post
That was a typo, David corrected the size on the next post to 17/64".

Drill and tap melted battery terminal?
Yep, that was my thoughts exactly.... good looking out and great info

I think my tap and die set is my best tool I have, saves alot of money thats for sure!
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Unread 06-11-2015, 10:02 AM   #7
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Default Re: Battery terminal post broke off

Another option is to contact a battery store about re-pouring the post.
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Unread 06-11-2015, 10:16 AM   #8
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Default Re: Battery terminal post broke off

If a recast is not an option...

Myself I would not use a 17/64" (.2656") bit for an 5/16"-18 bolt as this is going to result in slightly shallow threads which can make pull out easy in soft lead.... The proper bit is an F bit at .2570" to which in soft lead a 1/4" bit will give very nice results with no fear of tap breakage....
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Unread 06-11-2015, 10:18 AM   #9
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Default Re: Battery terminal post broke off

Just asking out of curiosity, because I am not a sparky, but why could you not cut off the end of the cable, fit one of these and use the undamaged post.

Dave
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Unread 06-11-2015, 10:33 AM   #10
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Default Re: Battery terminal post broke off

Quote:
Originally Posted by Dave Box View Post
Just asking out of curiosity, because I am not a sparky, but why could you not cut off the end of the cable, fit one of these and use the undamaged post.

Dave
Hard to tell from the OP post if that is a full height DT terminal or just a nub from a ELPT terminal....
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