What hardware to use to connect batteries and contactors?

[Johno7656]

I have done some searching on this topic and I have not found my answer.

I have a 1991 EZGO that I am doing a complete re-build and I am now coming up on the part where I install the electrics. I am trying to determine what is the best hardware to use to make the connections to the batteries and other high amperage devices and I need some advice.

If I use standard hardware store nuts and bolts, they will rust and or corrode over time. Copper would be great only I cannot find source for it. I had some problems (heat) with dissimilar metals when I tried to use stainless steel on an application some years ago.

So my question is what types of nuts / bolts / washers come on these carts from the factory? What hardware would be ideal if you had the choice?

Thanks in advance for any input. John

[TheWiltz]

The threaded stud on the battery is steel...

If you could find copper nuts, you could probably replace your steel nuts and washers 4 times a year for life of your batteries for the cost of copper nuts.

Just my thoughts. Good luck.

[JohnnieB]

I believe carts come from the factory with Lead battery posts, stainless steel studs & nuts and copper or tinned copper cables lugs.
As far as I know, no washers are used in any electrical connections on golf carts.

The primary electrical connection on a cart battery is Lead to Copper and the stainless steel stud & nut holds the two together while providing a secondary current path.
The stud is actually a hex-head bolt embedded in Lead, so the torque limit on the nut is about 10 ft-lb (80-120 in-lb is the Trojan battery spec)

The acid laden air above the batteries corrodes both Lead and Copper, so a terminal protectorate is needed.
I've been looking for a product that both protects and is conductive, but doesn't cost an arm and leg.
Here is the thread:http://www.buggiesgonewild.com/elect...al-grease.html

Loose and/or corroded battery connections will cause heat, in fact it has melted the terminals off batteries, but with a proper battery maintenance routine, it isn't an issue.

[Johno7656]

Thanks for the responses. I will be in an area tomorrow where I can get some SS hardware so I guess that is the route I will take. Thanks again. John