BYD terminal problem

[Samshead]

I’m finally putting together my BYD packs I bought from Battery Hookup. So far all is going smoothly but one of the terminals appears to have gotten broken. I didn’t notice it until I was assembling the bms. The welds in the positive terminal have come loose. Are there any suggestions for a repair? Thanks!

 

[Hedges]

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"Installation requires access to both sides of the panel."
But seems to me just enough access to hold the nut with angled tweezers or forceps. Drill a hole, put nut under, use a bolt to pull it into the hole.

A piece of sheetmetal as a guard for the cell would be good while drilling.

 

[Samshead]

A little confused. The welds that connect the plate that has the terminal post to the actual cell have broken. The cell is ok and takes a charge but I’m sure that any appreciable current would create a problem.

 

[Ampster]

A little confused. The welds that connect the plate that has the terminal post to the actual cell have broken.

Do you have a picture of one that is not broken for comparison?

 

[Samshead]

They look the same but here is the negative side and the positive with the terminal plate detached.

 

[Hedges]

I thought the problem was a stud welded to the plate and standing up had broken off.
This looks like a stud coming from the battery through a hole in the plate. Was welded to the plate but broke so now just rubbing in the hole?

If so, best solution is someone who can (probably laser) weld it back on.

I imagined for a moment drill - tap - bolt but it doesn't have good contact surfaces and you'd have to address oxide.

 

[stephenwolf2]

I’ve got a couple that got the studs disconnected in shipping like this… did you end up fixing yours?