Melted Battery Post....WTH?

[zero26tb4u]

I've seen a few posts here about melted battery posts but not this bad.

Trojan batteries are less than a year old, brand new cables, corrosion spray, and torqued to specs.

What would have caused such a bad failure?

[PingEye3]

Probably, though 'torqued to specs', an over tightened cable loosened the stud embedded in the lead causing it to overheat is the cause. Definitely a loose connection cause it at that spot.

[zero26tb4u]

Very weird. I was very careful not to overtighten. I even bought a new torque wrench for this reason.

Would this happen after 11 months of use?

[PingEye3]

Originally Posted by zero26tb4u

Very weird. I was very careful not to overtighten. I even bought a new torque wrench for this reason. Just to make sure, it was an inch/lb torque wrench?

Would this happen after 11 months of use?

It could happen in the first month if there was a loose connection to cause high resistance and heat up. It is very possible that it was slightly loose inside when new, but with what happened, Trojan would not warranty it saying you 'over tightened' the connection, torque wrench or not.

[rib33024]

You can fix that battery post

https://www.buggiesgonewild.com/batt...nal-repair.php

[JohnnieB]

Originally Posted by zero26tb4u

Very weird. I was very careful not to overtighten. I even bought a new torque wrench for this reason.

Would this happen after 11 months of use?

The stud is a hex head bolt embedded in lead, so bumping it, dropping something on it or pulling on the cable could move the hard bolt head in the soft metal with results similar to what happens with over-tightening.

Could have been bumped during shipping, at the battery store or while installing, or afterwards. Not saying that is what happened, only that it could happen.

[ThreeCW]

Heat is generated due to resistance in the connection or in the cable.

To eliminate both possibilities, I would suggest to also replace the cable of the affected melted connection (using a good quality cable and connector ... try to avoid the imported economy cables).

I have also attached a copy of the Trojan Battery paper on faulty connections for your review.

[cgtech]

Also, the terminals should be checked at minimum every 6 months.

[wingnut2000]

I just did the drill and tap repair on my main battery post +. Its easy, basically drill a hole and thread it and install a stud in the hole.