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Old 08-07-2011, 01:19 PM   #1
go EZ
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Default Tools for working on electronics

In working my way through my first cart, one thing has become painfully obvious - Due to the closeness of connectors on say a controller (1204) and the fact that terminals have the wire run right up beside the connector, I can't get a socket on the connector to remove the nut, I don't want to and can't if I did get an adjustable or open end wrench on the connector nut. Many times I just sign and say oh no, here I go with a pair of needle nose pliers again.
What is the trick guys?
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Old 08-07-2011, 02:42 PM   #2
JohnnieB
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Default Re: Tools for working on electronics

I've never worked on a 1204 controller, but I have used thin walled 1/4" drive sockets on a flexible shaft and/or universal joints along with ignition wrenches to work in some pretty tight places.

Just remember, somebody had to put those wires one, so try to get inside his head. There must be a tool other than needle nose pliers that will work.

Post a picture of what you are up against and maybe someone will pop up with the exact tool you need.
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Old 08-07-2011, 02:53 PM   #3
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Default Re: Tools for working on electronics

I use these a lot. they get into corners great.
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Old 08-07-2011, 07:32 PM   #4
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Default Re: Tools for working on electronics

Invest in a quality set of Tappet wrenches.

http://www.sears.com/shc/s/p_10153_1...1&blockType=G1

While you are at it, buy an extra 9/16 X 1/2 as that one is the most common you will need 2 of at a time.
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Old 08-08-2011, 06:04 AM   #5
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Default Re: Tools for working on electronics

Thanks a lot guys.
And do you insulate them with something? The plastic dip material or just tape? I am still gun shy after shorting 36 volts/1350 amps and burning a hole through the top of batteries on my first outing under the hood.
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Old 08-08-2011, 07:25 AM   #6
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Default Re: Tools for working on electronics

Honestly, I work with my tools everyday and I have never done what you did..... No, I don't have mine insulated, but I can understand where someone might want to.
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Old 08-08-2011, 09:15 AM   #7
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Default Re: Tools for working on electronics

Quote:
Originally Posted by go EZ View Post
Thanks a lot guys.
And do you insulate them with something? The plastic dip material or just tape? I am still gun shy after shorting 36 volts/1350 amps and burning a hole through the top of batteries on my first outing under the hood.
First, we need to take a more objective look at your "successful failure" of a Darwin Test.
You were not permanently blinded by the flash.
Five of the six batteries were salvageable.
Your garage didn't burn down.
You now have a wrench that is suitable for framing and telling wild stories about.
And most of all, you are still permitted to donate to the gene pool of future generations.

As for insulating tools, there are two schools of thought that have been debated by worker safety professionals in committees and argued over beers by the rest of us, for years with no clear winner.

Personally, I subscribe to the theory that insulated tools have the tendency to give workers a false sense of security in situations where knowledge, due care and caution are needed.

I try my best not to work on live circuits, but that is not always possible, and when I must, I do so with the knowledge that it is a live circuit and a false move could cause great bodily harm to me or whatever I'm working on. On the rare occasions I do work on live circuits that contain lethal voltages, I use non-conductive gloves rather than insulated tools.

If your wrench on the battery posts has given you a phobia, you might try draping the operating field like a surgeon does the next time you work on the batteries. Cut a 2"x2" hole in the middle of a shower curtain and position the hole over the terminal you are working on, covering everything else with an non-conductive material so a dropped wrench won't cause a pyrotechnic display.

Hope this helps,
John
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Old 08-08-2011, 09:38 AM   #8
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Default Re: Tools for working on electronics

Good advice all.
The circuit was dead to me for all intents and purposes as I had disconnected the positive wires from the battery pack before beginning work. But alas, we all know that batteries still carry a charge from post to post regardless if wires are disconnected or not.
I will not turn wrenches in a battery compartment again without my face shield on - whether or not the area is draped. It was one of those groggy early morning moments when I thought I would fit a little work in.
And by the way, all batteries were salvaged. See my post on that for what could be some enlightening info.
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