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Basics for putting lugs on posts

Basics for putting lugs on posts 2024-01-07

Click on the Orange
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button at the top of the page to get the document.

I saw some folks on the forum that were assembling lugs onto their cells incorrectly so I thought it might be useful to document how to do it.

Click on the orange 'download' button to get the document.
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As with all the content I develop, corrections, comments, suggestions and reviews are always welcome.

Edits:
  1. Emphasized that putting post or screw in and out of the cell terminal will damage the cell terminal threads.
  2. Added page about stud lengths
  3. Added page about through-hole bus bars.

Note: This resource is a duplicate of the resource of the same name in the 'Beginners' section. This resource is linked to the same download file.
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FilterGuy
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I was about to start a new thread and the last thing I did was a search for stud only in Resource section. This literally has everything a newbie needs except the loctite product (533) seems wrong and not sure what torque level to use.

The loctite referred product link goes to 533. The 533 doesn't seem to be a good fit here. I did some research and my conclusions are in this post : https://diysolarforum.com/threads/pros-cons-to-use-loctite-on-grub-screws-on-eve-cells.20766/post-970902

Loctite 243 or 263 seems a much better choice and don't require primer.

Someone in the reviews below mentioned loctite red requires primer. That's not true for all loctite. Read my post above for more info.

The torque spec for Eve 105Ah M4 bolt says 8nm with an inserted screw at 6mm. With loctite in place, once dried is the maximum torque still 8nm? I think it is because the soft aluminum thread are still the weakest point regardless of the loctite. Perhaps I'm wrong?

I'm not planning to go above the recommended spec but to make sure nobody thinks loctite increases the "screw in torque" , perhaps consider added a note on this topic.

Thank you.
FilterGuy
FilterGuy
There may have been some confusion due to the file name in the Loctite Tutorial l linked to. The '533' in the middle of the name is not referring to Loctite 533 Industrial Adhesive. The document is a 'Loctite 101' about uses and types of Loctite. The Red Loctite 263 mentioned by @SunSolaris is a good choice.

I had never even considered the possibility someone would think Loctite would somehow change the torque requirements. Loctite only prevents rotation, it does not strengthen the threads.

I will update the document to clarify both points
Great info. Thanks for putting this all together. Regarding attaching the bus bars to the aluminum battery posts, isn't it a good idea to put a conductive anti oxidant like Noalox between the plated copper bus bars and the aluminum battery terminal? This would also be a good place to mention that bare copper bus bars on aluminum can result in galvanic corrosion and tin or nickel plated bus bars are a better choice. One more thing: red Loctite doesn't harden so well with stainless and aluminum. A touch of Loctite primer (e.g. Loctite 7649) promote hardening.
I really like the diagram and really in-depth explanation of something one thinks is simple but in reality needs to be done exactly right for optimal results. Thank you.
All of your content is very helpful for us beginners. Look forward to any more that you create. Thanks!
Thanks!
Plain and simple good advice
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