Monday, October 14, 2013

BATTERY CONNECTORS

Finding battery connectors at a reasonable price has proven to be quite a challenge. When I purchased new used batteries from a guy in California, they were supposed to be included but never arrived in any of the shipments, as he promised.

I made a 12V battery using #10 wire and crimp connectors to operate the Powerlab Cellpro 8, while bottom balancing the batteries but then, did not have any way to give the batteries the initial charge.


12 VOLT BATTERY WITH #10 CONNECTORS
 
The flexible connectors range any where from au$2.80 ea for order of 100, from a company in Austraila (freight is $160 to get them to the US,) to $7 , to $9 for the connector with SS bolts and Nordlock washers. In a previous post, one of you commented that the solid copper connectors could be purchased from a battery manufacturer, so I contacted a battery company and indeed,  was quoted a price, including the ss hex head bolt and regular split lock washer for delivery in September. I never heard from them again and do not receive a reply when emailing them, so I guess that was a dead end.

Just so I can go ahead and get an initial charge on the batteries, I contacted a local metal distributor and purchased 1" x 1/8" in bus bar and a bolt distributor to purchase SS M8 x 1.25 socket button head cap screws and wedge lock washers (The button head cap screws will look great and give a nice streamlined look to the battery connection.) Originally, I thought the washers were only made by Nord-Lock but found they are also made by a company named HEICO-LOCK. Heico-Lock would not supply them to me directly but the distributor I contacted could supply either brand.


JIG TO DRILL BUS BAR


CUTTING BUS BAR TO LENGTH


BUS BAR ON BATTERY TERMINALS
As a reality check, I contacted a company in China that makes ground straps and electrical hardware for the electric utility industry and got a quote. The disadvantage with ordering straps from a manufacturer in China is the minimum quantity required to place an order is significant. The advantage is the price per connector is not. As I only need 38, the cost for the minimum order would be way over what I would pay if I bought them for $9 each with bolts and Nord-Locks included.

Back in the late 80's and early 90's, my wife and I collected antique glassware. We would get up early every weekend to get to flea markets before sunrise to be the first to get to the good glassware as the vendors were putting it on their tables. Then we would bring it home to add to our collection, list it on our website, or put it on ebay to sell. So just as selling glassware was part of our collecting hobby, maybe selling EV components could go nicely with an EV building hobby.

The 51mm center to center connectors will work on HiPower 100AH cells possibly others. Would any of you be interested in 51MM center to center flexible connectors with SS M8 socket button head cap screws and wedge-lock washers for say, $5.50 each? You would need to pay shipping from Ohio to your location. I have an EBAY account with a 100% positive feedback rating, dating back 10 years, so you could purchase with confidence and it wouldn't be a group buy, where you would need to put money up front.


BATTERY CONNECTOR DIMENSIONS


BATTERY CONNECTOR




SS M8 SOCKET BUTTON HEAD CAP SCREW


WEDGE LOCK WASHER

So, the quest to do a quality build for under $10,000 continues and maybe if a builder could off set come of the cost by selling surpluses from the project while still giving other converters a better deal that available otherwise, would be a good deal all the way around. Any thoughts?

Until next time,

Randy 
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