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This !@%$# battery terminal!

StangTime

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So I have been gradually upgrading the audio system in this car. It has been an uphill battle all the way and then some. Finally getting to where I need to hook up a 4ga wire to the + battery terminal. That should be easy I say. Everyone else has done it. I can too. Wrong!

I attached this ring terminal to the end of my fuse block wire:
SSRT4HS-2.webp


The + battery terminal have wedges that are used to tighten the terminal to the battery post. They are coated with black oxide to reduce corrosion. That also makes them a poor surface for conduction.... ok move on to another solution. I saw in another post that somebody used the clamping bar that goes through the battery terminal to attach a ring terminal. I can do that instead... nope. Took apart the terminal clamp and discovered my ring terminal hole is too narrow for the flat bar to go through so I enlarged the hole. Thought I was on my way and then when reassembling the clamp. the bolt with the square head would not go up through the hole in the flat bar because my ring terminal was too thick... of course. So now I'm at the point where I'm getting so annoyed with it that I want to rip that mother effing battery terminal off altogether. That would be easy if the + terminal was like the - terminal and was attached with a nut. Nope... the + battery terminal is crimped to the wire and cannot be removed without some destructiveness. Thanks Ford.

I have 2 options at this point. Machine down the ring terminal so it's thin enough to work with the clamping mechanism, reducing it's strength and creating the possibility that it will crack. The ring terminal is about 0.25" thick and I would need to machine it down to 0.10"
Or cut-off the OEM battery terminal and use some after market multi conductor post and hope that I can get the heavy gauge + wires to be secured well enough.

Anyone replaced the OEM + battery terminal with something else? Looking for ideas.
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OF5.0

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So I have been gradually upgrading the audio system in this car. It has been an uphill battle all the way and then some. Finally getting to where I need to hook up a 4ga wire to the + battery terminal. That should be easy I say. Everyone else has done it. I can too. Wrong!

I attached this ring terminal to the end of my fuse block wire:
SSRT4HS-2.webp


The + battery terminal have wedges that are used to tighten the terminal to the battery post. They are coated with black oxide to reduce corrosion. That also makes them a poor surface for conduction.... ok move on to another solution. I saw in another post that somebody used the clamping bar that goes through the battery terminal to attach a ring terminal. I can do that instead... nope. Took apart the terminal clamp and discovered my ring terminal hole is too narrow for the flat bar to go through so I enlarged the hole. Thought I was on my way and then when reassembling the clamp. the bolt with the square head would not go up through the hole in the flat bar because my ring terminal was too thick... of course. So now I'm at the point where I'm getting so annoyed with it that I want to rip that mother effing battery terminal off altogether. That would be easy if the + terminal was like the - terminal and was attached with a nut. Nope... the + battery terminal is crimped to the wire and cannot be removed without some destructiveness. Thanks Ford.

I have 2 options at this point. Machine down the ring terminal so it's thin enough to work with the clamping mechanism, reducing it's strength and creating the possibility that it will crack. The ring terminal is about 0.25" thick and I would need to machine it down to 0.10"
Or cut-off the OEM battery terminal and use some after market multi conductor post and hope that I can get the heavy gauge + wires to be secured well enough.

Anyone replaced the OEM + battery terminal with something else? Looking for ideas.
I’ve seen fuse holders that mount on the top post to allow for one or more fuses and they add a side post for the original battery connection to avoid cutting the OEM battery cable. That may be another option.
 
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StangTime

StangTime

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I’ve seen fuse holders that mount on the top post to allow for one or more fuses and they add a side post for the original battery connection to avoid cutting the OEM battery cable. That may be another option.
I've seen them too and those are nice but they won't fit on our batteries with the limited room around the terminals. Those work only on flat top batteries.
 
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StangTime

StangTime

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I am going to try removing the black oxide coating from the clamp and bolting my ring terminal to the top. That might be good enough to make a solid connection. Going to move the battery tender connection to the fuse box so it's out of the way. One last attempt before I commit to lopping off the OEM.
 

Racemaster

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StangTime

StangTime

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https://www.mustang6g.com/forums/threads/battery-connection.97114/#post-2129987.

I mounted the fuse block inside the battery box so all cables are hidden.
That's pretty ingenious actually but my terminal won't do a back bend. :crazy:

I sanded smooth the clamp parts removing the black coating on the mating surfaces to get good surface contact and bolted the terminal down with the top nut. Turned out ok and I didn't need to throw more money at it. Trimmed the battery cover a bit to clear the new wires and it's ready to install the fuse. Next is to create mounting surface on top of the strut tower to provide a firm attachment point for the fuse holder.
20200728_194231.jpg
20200728_194259.jpg
20200728_194900.jpg


This shows how I ran the power wire going to the trunk around the left side of the battery box.
20200727_194529.jpg


Drilled a hole using a step drill just below the cabin air intake. This is the perfect spot as it puts the wire in a very accessible location just above the passenger carpet. A PCV valve grommet sealed the hole and protects the wire. Some Butyl rubber around the wire to prevent water getting in. Also drooped the wire downward before going through the firewall so any water that gets on it would have to run uphill to get to the grommet.
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