Re: (ET) cable terminals

["harry landis" <hlandis hotmail com>]

For those who like the lead clamp on terminals, you can take a regular cheap 
one with the steel clamp and throw away the clamp and bolts and solder the 
cable directly to the lead. Lead melts at a higher temp than solder, and 
solders easily if youy don't overheat it and melt it. Tin the cable first by 
smearing on flux and dipping it in molten lead or solder. You may have to do 
it a couple of times to get a good coating. Tinned wire works best, and also 
will have fewer corrosion issues. But it should also be tinned as above to 
bond the srtrands together before soldering to the terminal. A propane torch 
works fine. Electronic or plumber's 50/50 solder is fine. Don't use lead 
free solder as it melts at a higher temp.

Harry Landis

From: "David Roden (Akron OH USA)" <roden ald net>
To: Elec-trak cosmos phy tufts edu
Subject: Re: (ET) cable terminals
Date: Fri, 04 Feb 2005 00:13:34 -0500

On 2 Feb 2005 at 22:27, Chris Zach wrote:

>  From what I've heard on the EV lists, the problem with the ring and
> stud is that the bolt comes loose over time which leads to a loose cable 
which
> leads to a melted post.

I hear this a lot, and I have no doubt that the combination terminals that
golf cars often use are not the optimum.  However, I have never had 
problems
with these terminals, either on the ET or on a road EV with a current limit 
of
anywhere from 250 to 400 amps.  I use ordinary split washers combined with
flat washers - not even Bellville washers - and just apply a wrench 
(gently)
every few months.

So far, the only battery connection I ever had fail was the cruddy generic
bolt-on clamp terminal that I used "temporarily" (uh, yeah, that's it ;-) 
on
my Comuta-Car.

If you are running a 700 or 1000 amp controller, no question about it - you
need the absolute best connection possible.  But at the currents the ET
requires, it's not such a big deal, IMO.  Use good stuff, but don't spend 
your
entire allowance on high-priced lugs or clamps.


David Roden - Akron, Ohio, USA
1991 Solectria Force 144vac
1991 Ford Escort Green/EV 128vdc
1970 GE Elec-trak E15 36vdc
1974 Avco New Idea 36vdc
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