Battery post repair part III
 

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I'm nothing if not persistent. I had buggered the post on a new battery and was looking for a way to repair it. I got some good comments here, both positive and negative. I tried the repair using some very old solder I had laying around but it didn't survive the bolt tightening. And I think it was plumbing solder. So I took OlAndrew's advice and tried electronic solder, (60% lead). I left a small steel nut inside the post with a 6x1 bolt in it when I did the soldering. The bolt had a bit of vaseline on it to keep it from binding to the solder (thanks Cogswell). When the soldering was finished I removed the bolt and after a bit of filing and finishing and cleaning up the threads with a 6x1 tap I was left with this result. It's in the bike now and so far it works. The question is one of reliability and longevity. My next extended road trip isn't until September so I'll be riding local for the next several weeks. Hopefully it will survive. If not I'll buy a new one and chalk this up to one of life's lessons.

I'll keep an eye on it and let you know how it works out.

I could have really used this post a few months ago. I busted the post on a 3 month old battery while I was super medicated after having my shoulder rebuilt. I tried to fix it and failed miserably.

Man this is above my pay grade. I prolly would have drilled a hole in the side and used a nut and a bolt.

Dave if I can do it anyone can do it.

If I understand.

You created a steel cage to surround the broken post.
Used a Soldering Iron as the tool.
Used 100% lead electrical solder as the fill.
Vaselined a bolt and inserted the bolt into the broken post's remaining threads.
Melted the lead w/ the iron into the cage.
Removed bolt, re-tapped the threads.
Filed to shape and smoothed with hand filing tools while retaining the cage.
No plan to remove the cage and it is now part of the battery post.

I think this is an excellent repair.
Thank's for your story and the thread.

Good job ... especially enduring the "Forum Crap"


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Nice job
 

You said it OP, persistent. Personally my time is worth much more than that. And to possibly face a failure going down the road at a later date? Shoot, I would be pulling the seat off every ride, and again, my time is more valuable. Best of luck to ya though!!!

Pretty much as you said Kenny. Some minor corrections.








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Looks like you buggered it in late June. Month of not riding worth the savings? Kudos for tenacity