DIY battery terminal connections

[Mike90250]

Well, nearly all prepped and ready to install the new batteries. However, there appear to be no terminal lugs in the size I need, that fit the batteries, so I'm going to have to make a "super lug" by bolting a regular crimp lug to a tinned, flattened piece of 1" copper pipe.

I'd been playing around the last week with different arrangements, and will have to get the big torch out, and melt the lead pot last used to cast a toilet flange! I'll dip the pipe into the lead, and tin it, then flatten and drill for thru bolts (not relying on solder) and will install the crimped lug, and sweat solder it, and use SS bolt with lock nut to anchor it all.

20mm (3/4") battery terminals are huge! The 30mm socket is from the auto parts store for mounting front wheel axle nuts.

Photo is from mock-up ver 2.0 (only had small butane micro torch to solder with) V3 will be the real deal.

[Iron Bran]

copper or nickel plated copper

Hi, I was just working on this very issue, and have been advised that a pure copper connection of any sort will begin to corrode in as little as three months.

For my test, we are going to use nickel plated copper to connect the battery cycler to the cells. Just a thought.

[Mike90250]

Hi, I was just working on this very issue, and have been advised that a pure copper connection of any sort will begin to corrode in as little as three months.
For my test, we are going to use nickel plated copper to connect the battery cycler to the cells. Just a thought.

That's why I'm gong to tin the copper with 50/50 solder, in a dip solder pot. An iron or torch will not do it properly. All the UL crimp lugs are "tin electroplate on copper". I don't know of any nickle plated lugs, likely the nickle won't crimp well.

[Mike90250]

That's why I'm gong to tin the copper with 50/50 solder, in a dip solder pot. An iron or torch will not do it properly. All the UL crimp lugs are "tin electroplate on copper". I don't know of any nickle plated lugs, likely the nickle won't crimp well.

today's update :
1) zinc chloride flux now banned in Calif - McMaster can't sell it in Calif. So that means the first tinning of the copper tube, pre flattning, will be with less good flux. At least I can still get 50/50 solder, and will have to use some nasty solvent to wash out the flux before flattening the pipe

2) the 3/8 holes drill out wonderfully on a nice drill press, and hand held should be ok too. I ran a pilot hole, and then the large drill.

3) the hole punch (3/4" chassis punch) uses a 3/8 drive screw, so that works just fine. The thick copper appears to cut cleanly, and the "plug" that came out of the punch, was still soldered together, even from the butane pencil torch. I think I may just fire the solder pot up a 2nd time, and use that for reflow, after flattening, instead of the big torch, I think it will leave a better finish

4) I will have to either offset the lug and terminal bolt holes, or lengthen the pipe to 2.25", to gain clearance to get the nuts to clear each other

[Iron Bran]

Electrolyte fill

Mike,

When you get to the electrolyte fill, I recommend the mix in bucket / use battery powered siphon pump to fill - method.

Sorry for the long link, you can also Google search battery powered siphon pump. I got mine at Lowe's. Less pouring equals safer fill.

http://www.google.com/search?aq=1&oq=battery+powered+siphon&gcx=c&sourceid=chrome&ie=UTF-8&q=battery+powered+siphon+pump#q=battery+powered+siphon+pump&hl=en&prmd=imvns&source=univ&tbm=shop&tbo=u&sa=X&ei=XRKTTrHHIeXbiAKD75nNCA&ved=0CHwQrQQ&bav=on.2,or.r_gc.r_pw.,cf.osb&fp=b07143d35d34e2f0&biw=1366&bih=667

PS

[Mike90250]

If I use a siphon/battery pump, I'll be there for a month. I've hopfuly selected a range of funnels that one will fit, and plan to mix 2 gallons at a time, in a 5 gallon pail. I bought new buckets, and a steel paint stirrer, that should acomplish the task, with minimal aireation. I've got 40 large batteries to fill and charge. I'll check the link you gave from home tonight, (apparently google and ebay are no longer worksafe - I get the red porn screen from the proxy server from them, and half of NASA too.)

[SteveC]

I used 1" copper pipe, too. I flattened one end, stuck the pipe in a vise, and used a step-drill bit to make the hole...just used a hand drill. Worked perfectly and didn't even have to file or otherwise clean up the hole. I have only been using the batteries for a couple months, so far no visible sign of corrosion/etc. on the plain copper pipe. However, I shall keep an eye on the homemade lugs. After two months, the copper looks as perfect as when I started. Fingers crossed.

My batteries came with an open-end wrench for the nuts. A big wrench.

[Mike90250]

Anyone know what the torque setting for the terminal bolts is ?? I've got two wrenches, but need to get adapters. I'm sure it's much less than normal torque of a 20mm bolt.

[Iron Bran]

ideas

If I use a siphon/battery pump, I'll be there for a month. I've hopfuly selected a range of funnels that one will fit, and plan to mix 2 gallons at a time, in a 5 gallon pail. I bought new buckets, and a steel paint stirrer, that should acomplish the task, with minimal aireation. I've got 40 large batteries to fill and charge. I'll check the link you gave from home tonight, (apparently google and ebay are no longer worksafe - I get the red porn screen from the proxy server from them, and half of NASA too.)

It must be the word "siphon" ....


Steel Stirrer I would recommend a non-reactive stir device... I dedicated a large plastic kitchen mixing spoon.

Bucket lid Careful when you carry an open bucket of liquid, the bucket caps fit tight and only cost about a dollar.

My battery operated pump used 2x D cells, and filled up a 500 amp hour cell very quickly. I find that bending while carefully holding a bucket over each cell took as much time, and took an even greater toll on my back. Working with a partner, the pouring method was fine because my partner could tell me how close I was to the fill line. [top view]

The pump was great when I worked alone because I was able to tell exactly how much liquid was in each cell. [side view] I promise, it goes quick.

[Mike90250]

... I find that bending while carefully holding a bucket over each cell took as much time, and took an even greater toll on my back. Working with a partner, the pouring method was fine because my partner could tell me how close I was to the fill line. [top view]

The pump was great when I worked alone because I was able to tell exactly how much liquid was in each cell. [side view] I promise, it goes quick.

I'll try that site when I get home, I agree about the back, just bending over the L-16's adding water was a pain.