Replacement D3 battery terminals

[Ooops]

Hi all

I'm looking for ideas for replacement battery terminal clamps for my D3
They could both do with being changed but the negative in particular needs sorting

I'd prefer not to replace them with the same thing so I'm looking for suggestions on alternative types and ideas on how to fit them.

The photos, borrowed from a Traxide post, show what's fitted currently fitted.

Thanks

images.jpeg1013.jpg

[Tombie]

May I ask why you want to do so?

[drivesafe]

Hi AG, and as Tombie asked?

The Positive ( + ) has a fuse built into it and you would need to install a new fuse setup.

The Negative ( - ) lead is used to monitor the cranking battery’s current flow, for the BMS.

You will need to do a lot of modifying to maintain the same type of setup

[Ooops]

May I ask why you want to do so?

Hi Tombie
The fittings have stretched, in particular the negative, presumably from over tightening, as a result it can't be sufficiently tightened.
At the very least I need to replace the negative clamp however I'd prefer not use the same style of clamp.
So I'm looking for a way to modify what i have or replace it.

I'm hoping its some thing that's been done by one or more of the members

[Ooops]

Hi Tim,

The Positive ( + ) has a fuse built into it and you would need to install a new fuse setup.

The Negative ( - ) lead is used to monitor the cranking battery’s current flow, for the BMS.

I was hoping there would be a way chop off the existing clamp portions on both leads and join the remainder into a new clamps, there by retaining the fuse and the negative lead.

I've no idea if it can or should be done hence the question

[Ooops]

Have I asked a really stupid question and every one's too polite to tell me?

[DiscoJeffster]

Have I asked a really stupid question and every one's too polite to tell me?

I believe you’ve asked a question with no easy answer as no one (edit: not many?) has had the issue? Did you do a forum search? As mentioned by Tim, the terminals on the discovery aren’t simple as there’s the battery monitor and fuse built in. Attempting to hack them to retain this won’t be easy. The simplest approach if you need to fix it would be replacement genuine leads including terminals. Failing that, take it to an auto sparky and seek advice?

[ytt105]

I can assure you that as the car ages these problems DO exist.

My negative terminal has always been a bit 'iffy' The last time I had it off I spent best part of 1/2hr cleaning, opening up, tapping down the bugger to get it back on tight.

I dare not touch it now.

So I've contemplated the best way to 're-do' the connection.

May need it one day in the never ever.

My 'idea', if stranded, would be to cut the bolt section off and fashion an oval stub from the resulting square section, then clamp that down on one of those clamp style battery terminals.


Regards
Trev
2005 TDV6

[Ooops]

Hi DiscoJeffster and ytt105, thanks for getting back to me

I can assure you that as the car ages these problems DO exist.

Thanks for that, I was beginning to think that it was just me

My negative terminal has always been a bit 'iffy' The last time I had it off I spent best part of 1/2hr cleaning, opening up, tapping down the bugger to get it back on tight. I dare not touch it now.

That’s exactly where I am now. I’m about to replace the alternator, the only way I can get the negative (-) clamp tight is by packing the inside of it with a sliver of soda can. Its pants

The simplest approach if you need to fix it would be replacement genuine leads including terminals.

IMHO the original clamp is less robust than other designs, if at all possible I’d prefer to use some thing else. In contrast to the original, the clamp that Tim supplied with his DB kit is bullet proof and similar to the one shown.
IMG_0119 copy.jpg

Failing that, take it to an auto sparky and seek advice?

I’m in the back end of nowhere, in a third world country, no such animal exists. The main stealer is a six hour round trip away and hopeless for this sort of thing

I've contemplated the best way to 're-do' the connection ......
My 'idea', if stranded, would be to cut the bolt section off and fashion an oval stub from the resulting square section, then clamp that down on one of those clamp style battery terminals.

Thank you Trev that’s exactly the sort of thing that I was looking for. Would you mind explaining your idea in a bit more detail?

For both sides I was thinking about cutting off the failed clamp and bolting the remaining bar into it a more traditional clamp.
IMG_0121 copy.jpgIMG_0123 copy.jpgIMG_0122 copy.jpg

I’m a bit worried about the bar portion of the original ending up being a little too short

I’m also unsure how the BMS works and whether changing the length of the solid metal work, or adding a different material, particularly on the negative will alter its function

Did you do a forum search?

I did an extensive search before asking.

As mentioned by Tim, the terminals on the discovery aren’t simple as there’s the battery monitor and fuse built in. Attempting to hack them to retain this won’t be easy.

Both points are understood. I'm not seeking to remove or replace either.
I'm merely looking for a way to replace the clamp portion.

I was asking if any one had successfully accomplished this. With the wealth of talent on here I felt it likely that some one had found a good solution. I’m not talented in this direction nor very innovative which is why I asked.

[DiscoJeffster]

I see no reason, height aside, why you couldn’t cut off that terminal, drill through the remainder and use a clamp like in those pictures. It will raise the height of it all so that’s the main consideration. In that last pic, drill a hole in the solid bit, cut off the old terminal, bolt down. Winner. Well maybe