The issue is hydrogen gas that may still be in the batteries after (over) charging. It's highly flammable in the atmosphere (20% oxygen), and within the battery space, the containment can be explosive.
The cover will also protect the battery tops from pitting from the landing sparks.
If you have moved the threaded stud within the cast-lead post, the integrity of the post may already be compromised anyway. There used to be a battery shop in my area that had the molds and equipment to reform/recast a damaged battery post, but they have been gone for years. I don't know if this is even done anymore.
Not suggesting this is a great idea, but if I was facing this, I would file off some thread from the post with a hand file on two sides to get a surface I could hold with strong vice-grips or a wrench, and try turning the nut against that leverage. If that works, the threads can be restored after by running the nut over them. (I would also be looking for a possible used replacement battery in case the post is not recoverable.)
Darryl McMahon On 4/19/2023 1:26 PM, Ken Olum wrote:
My understanding is that the ignition danger is connected with hydrogen
that might have been produced by electrolysis when the battery was
charged. I doubt you have a problem if you're sitting in an open space,
where the hydrogen would rapidly dissipate. To be sure you could take
the caps off the cells to let any explosive mixture in there dissipate
also. Then put them back on again before grinding.
Also very be careful about dealing with batteries with wires attached.
I got in trouble with this once when the free end of the wire touched
the other battery terminal. Fortunately I got away with only a small
amount of melted lead. Also, as usual, you want to make sure there's no
danger of short-circuits caused by tools. So carefully insulate the
terminal that you're not working on.
Ken
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-- Darryl McMahon Freelance Project Manager (sustainable systems) Do not mistake patience for weakness, nor action for strategy.