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Old 10-16-2008, 08:58 PM   #1 (permalink)
EV test pilot
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Join Date: Jan 2008
Location: Oconomowoc, WI, USA
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Electric Cycle - '81 Kawasaki KZ440
90 day: 334.6 mpg (US)

S10 - '95 Chevy S10
90 day: 30.48 mpg (US)

Electro-Metro - '96 Ben Nelson's "Electro-Metro"
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The Wife's Car - Plug-in Prius - '04 Toyota Prius
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Battery Post Repair

Remember when I melted the post on one of my Electric Motorcycle's batteries?
I am good at destroying electric motorcycles!

Then I tried fixing it myself?
How to Repair an Optima Yellow Top

A couple weeks ago, the cycle suddenly quit working. I narrowed the problem down to that battery post having gone bad again.

A couple guys mentioned to me about taking it to a battery place that could recast the post.

I finally got a referral to a place called Challenger Battery in Waukesha, WI. I called, and then stopped over there.

The guy there chopped off, and then re-cast the battery post while I chit-chatted with him about my electric vehicle projects. When I asked how much I owed him, he said "No charge, just come back here next time you want to buy a battery."

They were super-nice there. Hard to beat a donation of labor over buying a new $170 battery!!!

I said it looked as good as new. The guy corrected me, saying that it's actually better than new, because it's now a single, solid cast, whereas the original manufactured post is cast in two parts, which you can see in the photos of when I cut the post to do my repair

If anyone is looking to buy a battery, or repair a forklift battery, or starter motor, please patronize Challenger Battery!

Here's the new battery post!

PS: The new post is the shiny one! (negative post)



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Old 10-16-2008, 09:19 PM   #2 (permalink)
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Join Date: Dec 2007
Location: Germantown, WI
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CM400E - '81 Honda CM400E
90 day: 58.47 mpg (US)

Daox's Grey Prius - '04 Toyota Prius
Team Toyota
90 day: 53.65 mpg (US)

Daox's Metro - '99 Chevrolet Metro
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Wow, that is nice!
Current project: DIY electric water pump - on the cheap
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Old 10-16-2008, 11:48 PM   #3 (permalink)
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Join Date: Jan 2008
Location: up north
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Blue - '93 Ford Tempo
Last 3: 27.29 mpg (US)

ShWing! - '82 honda gold wing Interstate
90 day: 33.65 mpg (US)

F150 - '94 Ford F150 XLT 4x4
90 day: 18.5 mpg (US)

Sport Coupe - '92 Ford Tempo GL
Last 3: 69.62 mpg (US)

Moon Unit - '98 Mercury Sable LX Wagon
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Actual customer service?!?

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Old 10-17-2008, 02:39 AM   #4 (permalink)
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Absolutely unheard of!

Wish this guy was in NC, i'd drum up as much business for him as I could...
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Old 10-17-2008, 04:35 AM   #5 (permalink)
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battery post repair

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