Recently, I had a problem with one of the Optima batteries on my electric motorcycle.
I shorted out a post and melted it.
Today, I finally had some time to work on the cycle. I cleaned up some of the wiring and decided to fix the post too.
The first thing I did was cut the post off, as it really wasn't needed, because Yellow Tops have side posts as well, which is what I was using.
Of course the instant I cut the post off, the cycle no longer worked. Turns out that Optimas actually connect the cells internally through the POST!
So even though I cut the top post off, now the side posts no longer worked!
I called the battery store, where the guy informed me about the internal connection through the post. He also said there was no way to fix it, I just wrecked it, and by the way, I just lost my warranty too!
After getting off the phone, I got into an angry "I'll show him" mood.
I drilled a hole through both what was left of post and the bit I cut off.
I then tapped both parts.
I threaded a bolt through both parts and tightened it down.
Then I hit it with a torch to melt the lead back together, bit it was not narrow enough of a flame, so I finished off melting the lead seam together with a soldering iron.
Turned the cycle on - worked great again.
So there you go. Fix a $160 battery with a 10 cent bolt.
Take that! dude at the battery store!
(Please note that anytime you work with lead, don't breath any fumes, and wash your hands well after working. When working with batteries, always know where any conductive tools are and what's positive and negative!!!)
