HD F/R switch

[CartTrader]

Whats the difference between a standard F/R switch and a heavy duty one, besides the thick copper bars across the terminals on the back side? REASON, Upgrading a 96 CC 48v DS. And in the process bought a new HD F/R switch. Looking at the new HD and the old one. The only difference I can see is the thick copper bars across the back, where the standard is only 1/2 as thick and made of a material other than copper. My main reason for asking is as I was installing the new switch and being as the copper was thicker and the terminal I was using was thicker, it didn`t leave a lot of threads left for the nut and I stripped the @#%&# threads!! . Now do I just replace the thicker bars on the old one or take the terminal wiper bar off the old one and put it on the new one?

CartTrader

[shadowman]

did you strip the bolt hole or the bolt?...........................................

[CartTrader]

Copper stud that goes from the wiper contact in the front to the back to attach the cable to. Stud made of copper. Nut made of steel.

CartTrader

[scottyb]

Buy a new stud?

[arcitech]

More copper means it can handle more amperage, and have a larger contact area to get the best connection.

[CartTrader]

Originally Posted by arcitech

More copper means it can handle more amperage, and have a larger contact area to get the best connection.

Yes I know "more copper means more amperage" Not sure if the contact area of the wiper is larger on the HD vs the standard. They look the same.

Scottyb.....where could I get the new stud? Do they sell replacement parts for the F/R switch? The stud and the wiper contact are all one piece!!

CartTrader

[scottyb]

The stud has a big lug on the end of it? I'm sure somebody sells them .... they do for Ezgo

[CartTrader]

Originally Posted by scottyb

The stud has a big lug on the end of it? I'm sure somebody sells them .... they do for Ezgo

Yes the stud has a lug on the end of it. lug is about 1" long and 1/2" wide ..tapering a bit. Are those studs any different from the standard F/Rs? Haven`t measured but they look the same. Finding someone that sells them is going to be the problem. Thats why I was wondering if the only difference is the copper strips on the back of the switch!!

CartTrader

[scottyb]

I think you can throw the bigger buss bars in the old switch and give it a go..... too bad about not getting all the rest of the new parts to go with it. If your old contacts are worn and pitted you may not be gaining anything?

[CartTrader]

Worn Maybe..pitted no. Hate the fact that I spent that much for a HD switch and now can`t use it, unless I get a new lug-stud. AND thats all I need for this upgrade to be finished. Installed new wires 4awg. HD solenoid, F/R switch and an Altrax axe controller. With a high speed 8-1 rear, 6" jakes lift and 22" tires. Plus a NEW custom fiberglass body! In bright orange!! Going to call it "Orange Crush" !! Oh yea and a 36v motor running 48v!!! It would do a bit over 30 gps with the old oem controller and 6 awg wires, but was a bit slow on takeoff and the wires were getting a bit warm, along with the F/R switch.
By the way this has also been inspected, titled and licensed as an LSV, before this last upgrade of wires and controller.

CartTrader