Battery Post Stripped - 04 DS Electric

[dkbuckeye]

I have 6 8V Crown batteries on my 04 DS IQ cart. The last battery in the series evidently had a loose connection that arced. The battery is not swollen but there is some welded arcing visible on the base of the post (see attached photo). My voltage meter wire was cooked at the connection. The cable lead to the controller would probably be best to cut back 2” and use a new cable lug. My question is: if I use a marine terminal adapter on the unthreaded top post (photo attached), do I need to still drill out the threaded post and replace, or can I just leave it unused in place and operate off the unthreaded top post? I’d prefer to not drill into the battery and retap for a new post insert, but I also don’t want to break down or cause more damage. Thanks in advance

[rowlands57]

I cannot see any reason why that marine adapter would not work. However, I have read more than once here that crimping is best done using the proper tools, a 'home crimp' does not suffice. Again, that's not from personal experience but have read many warnings about it over my time lurking here.

[Capt. Lenny]

The marine terminals would be a simple, economical repair and should last a long time. Use a spray battery corrosion protector when done. The cable eye can be soldered on then cover with adhesive lined heat shrink tubing. If you have a battery shop nearby (Battery Wholesale did mine) see if they’ll crimp them for you.

[dkbuckeye]

Thanks. Do I need to cut the nut off the old post or can I leave it in place? There’s a little bit of movement in the old post. Is that ok?

[Capt. Lenny]

I would leave the old post. A little movement might not be good, could make for a loose connection internally that would produce heat. Drive the cart when repaired and use an infrared heat sensor and see if that terminal gets any hotter than any other.

[rowlands57]

It would seem that the nut would need to be cut off in order to place the new terminal is a way that won't interfere with the cap near that post. Not sure about the movement though.

[Frizbgolf]

just keep bending the old connector up and down it will break off

[dkbuckeye]

Thanks all. I’ll get on it by the weekend and provide an update

[dkbuckeye]

So….after I didn’t get the threaded post out after 15 minutes I checked with a local electrical shop about professionally crimping the cable. They were adamant that the battery would be unsafe if the post were removed. I bought a new battery and installed it. Batteries are reading 50.4V. Lights and tail lights work. No response from the pedal. Cart is inoperative. I switched it back to Run (from Tow). Is there a fuse somewhere or another connection I’m missing? This is frustrating

[dkbuckeye]

OBC was bad. Bypassed it and installed a Lester Summit II onboard charger that I already had and was installing this week anyway.