How to Make Battery Pole | Battery Terminal Repair & New Pole Making | Battery Repairing, by King Autos on YouTube. 2 min 33 s.
- Video length
- 2 min 33 s
- Time to do it
- 45 minutes
- Difficulty
- Medium
- Steps
- 8
What you need
Steps
Work outdoors or in a well-ventilated space. Put on gloves, eye protection and a respirator, and keep a fire extinguisher and a bucket of sand nearby. Lead fumes are toxic.
Disconnect the negative cable first, then the positive, and lift the battery out of the car onto a metal tray. Never cast lead with the battery connected.
Clean the damaged post and the cable clamp with a wire brush. Neutralise any acid residue with baking soda and water, then dry everything.
Fit the terminal mold over the post and clamp it tight. Check it sits level, so the new pole comes out straight and the cable clamp will fit.
Melt lead scrap in a ladle with a torch until it flows like water. Skim the grey dross off the top with a metal spoon before pouring.
Pour the molten lead slowly into the mold in one steady stream until it reaches the top. Let it cool for 10 to 15 minutes without touching it.
Open the mold and lift it off. File or sand the top of the new pole flat and ream the taper so the clamp sits down fully.
Refit the battery, connect the positive cable first, then the negative. Tighten the clamps and coat both posts with petroleum jelly or terminal grease.
Tips and common mistakes
Never melt lead on a kitchen stove or indoors, and keep every drop of water away from the molten metal.
A loose or corroded clamp is the usual reason a post overheats and melts, so fix the clamp too.
Wear old clothes and shoes you can throw away, and wash your hands before eating.
If the new pole keeps melting, have the charging system tested before you cast another one.
Questions
Can I make a battery pole without a mold?
You need a mold to shape the lead. Buy an inexpensive terminal mold, or pack a spare clamp with fire clay as a rough one-off form.
Is it safe to pour lead onto the post while the battery is still in the car?
No. A charging battery gives off hydrogen gas and acid can spit, so always take the battery out and work outside.
Why did my battery terminal melt in the first place?
Most often a loose or dirty clamp creates resistance and heat. Clean and tighten the clamps and check the charging voltage.
This guide was drafted from the video's details and general task knowledge. It has not been checked against the full video. Check the video and relevant product instructions before following a procedure. Report a correction.
