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Old 09-16-2007, 07:29 PM   #1
caddymankc
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Default Melted battery terminal repair

i melted down a terminal on my one battery luckily i found it before it melted through, the stud is still on there kinda but the nut is stuck, anybody got any tips on what i have to do, im just thinking of cutting off the stud and running a clamp terminal
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Old 09-16-2007, 07:54 PM   #2
roady89
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Default re: Melted battery terminal repair

More than likely have to cut it off. I have seen the clamp fix but I dont like it. You can drill and tap the lead to accept a stud. If you opt for the drill/tap method be sure and keep it dead center and only drill about 3/4 of an inch into the lead. Then you can tap for a 5/16-18 thread. Tap a few threads at a time and blow the shavings out. Keep tapping until you reach bottom. Some hardware stores carry those 5/16-18 allen studs. Tighten the stud and your done. I always use a stainless washer under my terminal ends so the corrosion is reduced to a minimum. This is probly the best "fix".
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Old 09-16-2007, 07:56 PM   #3
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Default re: Melted battery terminal repair

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Originally Posted by roady89 View Post
More than likely have to cut it off. I have seen the clamp fix but I dot like it. You can drill and tap the lead to accept a stud. If you opt for the drill/tap method be sure and keep it dead center and only drill about 3/4 of an inch into the lead. Then you can tap for a 5/16-18 thread. Tap a few threads at a time and blow the shavings out. Keep tapping until you reach bottom. Some hardware stores carry those 5/16-18 allen studs. Tighten the stud and your done. I always use a stainless washer uner my terminal ends so the corrosion is reduced to a minimum. This is probly the best "fix".

this works!!!Did this a year ago and still going strong
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Old 09-16-2007, 10:16 PM   #4
2stroke
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Default re: Melted battery terminal repair

One of the carts did this, i cut it off and put a marine clamp on it i havnt had any problems yet and its used for 18 holes a day
roady's suggestion is safer though but it's whatever you choose
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Old 09-17-2007, 06:24 PM   #5
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Default re: Melted battery terminal repair

I would do roady's fix.

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Old 09-27-2007, 07:03 AM   #6
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Default re: Melted battery terminal repair

just don't weld on the batteries... flammable and all...
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Old 10-28-2009, 03:09 PM   #7
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Default Re: Melted battery terminal repair

Roadys Repair Is Kosher,and Make Sure You Put Lockwasher Under All Your Nuts So They Wont Back Off And Burn Down Another Post.
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Old 10-28-2009, 04:34 PM   #8
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Default Re: Melted battery terminal repair

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Originally Posted by golfcarfixer View Post
Roadys Repair Is Kosher,and Make Sure You Put Lockwasher Under All Your Nuts So They Wont Back Off And Burn Down Another Post.
I disagree. Battery terminal posts are lead, and as such they will deform under pressure from a tightened nut. Lock washers won't stop this from happening. Adding another layer (lock washer) only gives corrosion another place to start. Snug the nuts often, weekly if necessary, and they'll be fine.
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Old 10-28-2009, 05:36 PM   #9
roady89
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Default Re: Melted battery terminal repair

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Originally Posted by gornoman View Post
I disagree. Battery terminal posts are lead, and as such they will deform under pressure from a tightened nut. Lock washers won't stop this from happening. Adding another layer (lock washer) only gives corrosion another place to start. Snug the nuts often, weekly if necessary, and they'll be fine.
I agree. I used to think adding stainless washers was the thing to do...NOPE, just do like g-man says any you'll be fine. MAKE SURE you check them AT LEAST once a month because the connetion WILL get loose. The WORST thing that can happen is the connection gets so hot the stud gets loose in the lead and the nut won't turn. At that point you have a cable stuck on the batt you can't get off without cutting it off.
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Old 03-12-2010, 11:21 AM   #10
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Default Re: Melted battery terminal repair

Ok...i used roadys fix to fix a melted post....problem is, without thinking about it, i used a 1/4" tap and socket set screw...seem to work ok, should i redo it with the 5/16" set screw or will i be ok?
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