Freak Trojan Battery Meltdown Incicent

[scottyb]

Originally Posted by pggroves

LOL! That was roady's thread on PU. Can't link it, but if you know the main URL, then just paste this after it (remove the space between the r & e of "repair") and it should bring up the vintage thread from October 2005 when we were all "over there."

"phpBB2/viewtopic.php?t=13479&highlight=battery+terminal+r epair"

PU OH.... Price Unlimited

[gornoman]

Found it!

Originally Posted by roady89

Here's an easy fix for those batteries that have a loose stud or melted terminal. When I say loose stud I mean the stud is loose in the lead not the nut is loose. If your stud is loose it will keep getting worse untill finally getting so hot it melts off!!!!. :D


Ok.. Your going to need the following items
1= 21/64 drill bit
1= 3/8 16 tap
1= 3/8 16 stud
1= Hand drill
1= 3/8 16 nut
a little Lock-tite.

You can subsitute the 3/8 stuff for 5/16 if you need too. I just figured bigger the better.

Now for the fun part!
Use a center punch to get a mark on center of the terminal. It is very important that the hole is as close to center as possible.


Now get out that drill and bit.


THIS STEP IS IMPORTANT..... PAY ATTENTION! Only drill 3/4 of an inch at the most. Under the top of the battery the lead steps down in size. So if you are off center and drill too deep you will end up with a leaker. But if you are at this point anything beats buying a new battery, so this is worth a shot at least. Stay straight as possible.


Now grab the tap..... Lead is very soft so just tap a few turns and remove the tap. Then blow out the lead shavings. Then tap some more untill you bottom out. Again Stay straight as possible.


The threads....


Now this stud you should be able to pick up at any hardware store. I have put lock-tite on some I have done. Seems to work pretty well. DO NOT USE A BOLT!!!Remember the lead is soft, so if you use a bolt the threads wont last long. Use some lock-tite so the stud will not back out when loosening the nut.


There you go. That junk battery you had is now usable again. Hey.....It beats spend $60 to $100 on a new battery.

[scottyb]

Hee HE, that thread is so old I kept hoping the camera would zoom out and
show Roady in his beads and fro

[gornoman]

Sticky it???

[roady89]

Originally Posted by gornoman

Sticky it???

Yea, I guess. There has been a rash of this lately. Lemme do a remake of it. There are a few things that need changing.

[hitmanharleyk]

Originally Posted by roady89

Yea, I guess. There has been a rash of this lately. Lemme do a remake of it. There are a few things that need changing.

This is great stuff and I think it should be a sticky !!!! I've linked this thread to one in the electric cart forum for another guy who is having to do the same thing to his wife's cart.
Because of this thread, if me or either of my brother in laws have this problem we will know how to fix it (or at least I will) !!!!

Thanks,
K

[roady89]

How to repair melted battery terminals

[injunear]

Originally Posted by gornoman

One small tidbit to add:
The solenoid should NOT activate from the keyswitch, but rather it should activate from a combination of keyswitch, direction selector, AND gas pedal application. Testing like this should be done with the rear axle raised on stands.

Umm, also I think the reed switch.......

[roady89]

Originally Posted by injunear

Umm, also I think the reed switch.......

Depends on what model ezgo. Not all ezgo's have a reed switch.

[gornoman]

Originally Posted by injunear

Umm, also I think the reed switch.......

Reed switch is bypassed on my cart college boy.