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Old 11-15-2008, 04:34 AM   #1
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Question Broken battery post problem

I bought my wife a used cart to be able to put around the house with. Mainly I did it to keep her from wearing my hunting cart out. I started by checking the voltage on the batteries and found I had one bad battery to change out. I went to clean the connections on the other batteries and got to one that the nut didnt want to break free on. I sprayed it with some WD-40 and let it soak. I came back to it and ended up breaking the post off of the top of the battery. I didnt think I put that much pressure on it but evidently I did. Can this be repaired without having to buy another battery? The battery still test out good and I hate to get rid of a good battery cause I messed up. I dont know if I can melt lead and put it between the post that broke off and the exsisting lead still on the battery. If anyone can give me advice on this I would appreciate it.
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Old 11-15-2008, 05:35 AM   #2
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Default Re: Broken battery post problem

Maybe this thread will help you, it explainsthe process of drilling and tapping a battery post.

New to Electric Golf Carts, Battery Maintenance Question
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Old 11-15-2008, 06:59 AM   #3
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Default Re: Broken battery post problem

WD40 is not a good rust or corrosion dissolver IMO use PB Blaster or some such product instead. WD is more suited to lube and assembly jobs.
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Old 11-15-2008, 07:24 AM   #4
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Default Re: Broken battery post problem

Thanks hitmanharleyk. That thread was helpful to fix my retardation. Scottyb, your right about the PB blaster. The WD was in arms reach of where my butt was planted at the time and well, the rest is history. Let me ask this question, what type of stud was he talking about using after it was tapped. I am assuming a more coarse thread type to get a little more bite but I have been bass ackwards in my assumptions before. Thanks guys for the help.
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Old 11-15-2008, 07:27 AM   #5
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Default Re: Broken battery post problem

I also think a coarse thread would be best in the soft lead material. Use a thread locker as well!
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Old 11-15-2008, 05:54 PM   #6
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Default Re: Broken battery post problem

Go to this thread, it has step by step instructions with pictures on page three.

Freak Trojan Battery Meltdown Incicent
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Old 11-15-2008, 08:21 PM   #7
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Default Re: Broken battery post problem

Simple fix- Just drill pilot hole in post (about 3/4 inch deep) and use 1/4 inch lag bolt. Make sure bolt isn't over 1 inch long.
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Old 11-15-2008, 08:26 PM   #8
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Default Re: Broken battery post problem

Just my opinion, but I wouldn't recommend using a bolt because of the lead being so soft, I think you would be inviting trouble down the road as you remove cables for cleaning during monthly or bi-monthly maintenance.

I'd rather install a new stud like in the above link.
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Old 11-15-2008, 08:49 PM   #9
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Default Re: Broken battery post problem

Battery terminal repair - The right way

PLEASE do NOT use a lag bolt...or any bolt at all for that matter.

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Old 11-15-2008, 09:35 PM   #10
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Default Re: Broken battery post problem

Thanks guys for the input. As soon as I get back to the states I will do it like it was posted in the terminal repair thread. I'm ready to get into this build with her cart. Of course she wants it "GIRLY" topped off with pink camo and the works. Should be interesting to see how it comes out.
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