Lt.Dan
Solar Wizard
I do not sell them personally. Michael does, so if you want some, just send him a message.
Improving Contact Area on Welded Stud Pads
- Thread starter Horsefly
- Start date
Horsefly
Solar Wizard
Well, it wouldn't be the first time I've misread my caliper.
It's one of the old-time mechanical ones. I should get a digital one.Horsefly
Solar Wizard
Right now there are a bunch of people reading your post that have been waiting for many days for any reply from Michael, so we're all going "Yeah, right."
Horsefly
Solar Wizard
So your new assignment is to find a 11.11mm drill bit.
Short_Shot
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Done.So your new assignment is to find a 11.11mm drill bit.
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Horsefly
Solar Wizard
And the price is right!
Lt.Dan
Solar Wizard
Hmm, I just noticed he hasn't logged in since Tuesday. I'll shoot him a text and see what's going on.
Stepandwolf
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found it....7/16 = .4375 = 11.1mmSo your new assignment is to find a 11.11mm drill bit.
Horsefly
Solar Wizard
Nah, that's 11.2mm.
Short_Shot
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Horsefly
Solar Wizard
Yep, you are right. I somehow saw only a single one after the decimal on the little calculator on my phone.
Stepandwolf
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I wouldn't want to drill the washers to the exact assumed width as I bet there is at least that much variance in the posts.
I wouldn't want to drill a washer at all. That's a huge PITA and rather sketchy for safety too. I have a high quality drill press vice and I wouldn't want to do it with that. Maybe there's a better way that I haven't thought of.
Stepandwolf
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I have drilled MANY washers in a former life as a mechanic. If I was hasty, I would use a pair of pliers to hold the washer, but that is good for breaking your wrist. No danger at all sticking a washer in a vise. How would it be different than anything else you drill? In fact, being soft aluminum it ought to be a breeze to drill.
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It being soft aluminum, if you clamp it tight in a vise, horizontally, wouldn't it deform the washer?
Stepandwolf
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understand the concern, but not an issue if done carefully.
Seems the solution has been found, just have to get the ones Lt.Dan made when Michael surfaces. I still haven't ordered my next set of batteries so I didn't make the choice to stud or not yet.
Lt.Dan
Solar Wizard
Definitely lol
The 1000 series aluminum i made was so soft that you could fold the washer in half with your two fingers
RobertGreen
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Not trying to threadjack, but while we're on the subject of the difficulties with welded studs, I'm surprised that I haven't seen anyone else using lugs like in this picture.
They're rated for flex wire, copper or aluminum which allows you to put a slightly curved piece of flex wire between two of these things rather than the solid bus bars. This makes it so that any slight movement or expansion of the cells won't put any strain on the battery terminals. And they run less than a dollar each, with all kinds of sizes available. Plus you can get them with 2 or more ports for wires to be added, so that you can connect the end terminals in the string both to the inverter/bus or whatever and to the next mating cell.
It also takes away any concerns about short welded studs running out of room as you stack a busbar, a double busbar, a inverter connection, the balance leads for the BMS, lockwashers etc etc. They seem to resolve several issues that are commonly encountered with making these packs.
They're rated for flex wire, copper or aluminum which allows you to put a slightly curved piece of flex wire between two of these things rather than the solid bus bars. This makes it so that any slight movement or expansion of the cells won't put any strain on the battery terminals. And they run less than a dollar each, with all kinds of sizes available. Plus you can get them with 2 or more ports for wires to be added, so that you can connect the end terminals in the string both to the inverter/bus or whatever and to the next mating cell.
It also takes away any concerns about short welded studs running out of room as you stack a busbar, a double busbar, a inverter connection, the balance leads for the BMS, lockwashers etc etc. They seem to resolve several issues that are commonly encountered with making these packs.
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