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  #26  
Old 03-13-2014
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Cool. Sounds good. Make me up a set of 3/4" terminals, let me know when they're ready and I'll send you the funds. If you don't mind post some pics of the finished product. I want them regardless, but you might as well let everyone see your handy work.
  #27  
Old 03-20-2014
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Here are some pics of a new set I'm doing for someone... you know who you are

From raw bar stock to rough sizing to rough drilling & tapping.























I'm doing a pair of these which are mirror images of each other.
There will be 2 battery post set screw options so he can use whichever he likes best... the short button head bolt will have a slim look while the longer allen head bolt will allow for clamping jumper cables.
I have a few more ideas for jumper cable posts & stuff but I wanted these to be really simple.
Next on the to-do list will be sanding all the marks down smooth & then it's on to polishing.

These are 3/4" thick and about 2" square. They will both have openings for 1x 4ga wire & 3x 8ga wires.
Just like mine, the battery post holes are tapered & are a snug fit so I'll be including some sandpaper so he can trim down his posts if needed. I've been using this old battery for testing the fit so I'm hoping they won't be too snug on a different battery.

The set screws on top won't be that long when the wires are installed & the screws are tightened down... there will be about 1/8" gap between the top of the terminals & the bottom of the screw heads. I just stuck 'em in there for a couple quick pics before I trimmed them to length.
More to come on these as I get more done to them.

I'll be applying a little antisieze compound to the threads of the screws & I'm looking for an quick easy way to package some dielectric grease to apply to the wires too. There's still a lot to do on these but they're coming along nicely.
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buggman project Custom Battery Terminals & Connectors (ky)-rawblockaluminum.jpg   buggman project Custom Battery Terminals & Connectors (ky)-roughcutchamfer.jpg   buggman project Custom Battery Terminals & Connectors (ky)-roughdrilledamptapped.jpg   buggman project Custom Battery Terminals & Connectors (ky)-leftfrontshortbolt.jpg   buggman project Custom Battery Terminals & Connectors (ky)-shortboltlefttop.jpg  

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buggman project Custom Battery Terminals & Connectors (ky)-toplongbolt.jpg  
  #28  
Old 03-20-2014
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Nice work man !

You are always thinking.

Ltr
  #29  
Old 03-20-2014
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Nice...
  #30  
Old 03-21-2014
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OK, so I forgot to take pics of the sanding process, but you can use your imagination to guess what they look like.

Here's what they turned out like after polishing... you'll have to forgive the dust & fingerprints on them I was in a hurry to get some pics done tonight.

























One last little touch I did to the bottom of these terminals...


No reason to sand & polish the entire bottom of the terminals, so I did about 1/4" around all the edges then sprayed on a couple coats of paint.

The set screws for the wires are screwed in all the way in the pics, in use the heads will be about 1/8" to 3/16" above the terminals. I didn't want the heads to rub the top of the terminals & this gives a little more flexibility when using different size wires... in case he needs to run a 10ga wire in the 8ga hole, he will have a few extra threads to screw down to hold down the slightly smaller wire.

Like my set, I milled a chamfer into all the edges to relieve any sharp edges. I never like to leave sharp edges that can get bumped or scratched. Also kinda gives them a "lighter" or "thinner" feel even though they're a full 3/4" thick.

They'll get another final polishing before they're ready to ship out. The swirl marks came from the paper towel I used to wipe 'em down... note to self: use softer paper towel to prevent swirl marks.

All the screws have anti-seize applied & I found a simple way to include some dielectric grease to apply to the ends of the wires before clamping them down.

Just like my set, I gave them the battery pull test... I lightly tightened one of the terminals (before I polished them to prevent any scratches) to the battery post & I could easily pick that side of the battery off the floor by the terminal without so much as a wiggle from the terminal.
I'll be including some sandpaper with the terminals so he can fine tune his battery posts in the event his posts are a hair larger than the tapered openings in the terminals.

You can see how much shorter these are compared to my 1" thick terminals... but they work perfectly for the 4ga & 8ga openings.
I might be able to use this 3/4" stock for 1/0ga openings, but there may not be enough room for the recesses that hide the bare wires. I'll have to do some experimenting to see what I can come up with.

I'll be including a set of longer post set bolts if you want to use them for jumper cable hookups too.
For now, these are almost ready to send out.
Unfortunately I couldn't find any extra sets of allen wrenches to send along with these, but all 3 screw sizes are standard SAE sizes that most guys will already have in their toolboxes anyhow
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buggman project Custom Battery Terminals & Connectors (ky)-negativeside.jpg   buggman project Custom Battery Terminals & Connectors (ky)-positiveside.jpg   buggman project Custom Battery Terminals & Connectors (ky)-bottompainted.jpg  
  #31  
Old 03-21-2014
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Looks good.
  #32  
Old 03-21-2014
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I bet he'll be a happy guy...
  #33  
Old 03-21-2014
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I hope so
  #34  
Old 03-24-2014
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Hey Buggman, look what the postman brought me today...




I don't know why I forgot to get a pic of the positive terminal by itself, but if you look at the negative terminal you can see me taking the picture. These are awesome, and they worked out perfectly for my wiring. Thanks a bunch.

Al
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  #35  
Old 03-24-2014
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Awesome man!
How did they fit? Hopefully not too snug nor too loose.
  #36  
Old 03-25-2014
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Like a glove! Perfect fit.
  #37  
Old 06-21-2015
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If your still makin and selling these I would like to discuss a payment. Can you email me at [email protected]
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