The Automobile Storage Battery Part 22

The guide-bar, or "comb," E, has slots along two sides, the base having corresponding slots, as shown. To accommodate different sized plates, the comb may be raised or lowered, and the uprights may be moved back and forth in two slots, one of which is shown at F. In using this rack, the plates are set in position, with their lower edges in the slots of the base, and their lugs in the slots in the comb. The plates are in this way held at opposite corners, and are absolutely straight and parallel.

Special fittings are provided to simplify the work of burning. A bar, D, fits along the edge of the comb, and holds the lugs of the plates firmly in the slots. This bar is movable to any part of the comb, being held by two spring clips, C. Two bars, A and B, which are adjustable, make a form around the plate lugs which will prevent the hot lead from running off while burning in the plates.

Instructions for burning on plates are given on page 217.

The triangular sc.r.a.per, steel wire brush, coa.r.s.e files and smoked or blue gla.s.ses are all standard articles and may be obtained from any supply house. The burning collars are made of iron, and are set over the end of inter-cell connectors when burning these to the posts, see Figure 98. Experienced repairmen generally do not use them, but those who have trouble with the whole end of the connector melting and the lead running off should use collars to hold in the lead.

[Fig. 98 Burning collars]

The Burning Lead Mould

In every shop there is an acc.u.mulation of sc.r.a.p lead from post drillings, old connecting straps, old plate straps, etc. These should be kept in a special box provided for that purpose, and when a sufficient amount has acc.u.mulated, the lead should be melted and run off into moulds for making burning-lead.

The Burning Lead Mould is designed to be used for this purpose. As shown in Fig. 99, the mould consists of a sheet iron form which has been pressed into six troughs or grooves into which the melted lead is poured. This sheet iron form is conveniently mounted on a block of wood which has a handle at one end, making it possible to hold the mould while hot without danger of being burned. A sheet of asbestos separates the iron form from the wood, thus protecting the wood from the heat of the melted lead. A hole is drilled in the end of the handle to permit the mould being hung on a nail when not in use. The grooves in the iron form will produce bars of burning lead 15 inches long, 5-16 inch thick, 3/8 inch wide at the top, and 1/4 inch wide at the bottom.

[Fig. 99]

Fig. 99. Burning-Lead Moulds, and Burning Sticks Cast in Them

The advantage of this type of Burning Lead Mould over a cast iron mould is obvious. The form, being made of sheet iron, heats up very quickly, and absorbs only a very small amount of heat from the melted lead. The cast-iron mould, on the other hand, takes so much heat from the melted lead that the latter cools very quickly, and is hard to handle.

An iron pot that will hold at least ten pounds of molten lead should be used in melting up lead sc.r.a.ps for burning sticks.

When the metal has become soft enough to stir with a clean pine stick skim off the dross. Continue heating metal until slightly yellow on top.

With a paddle or ladle drop in a cleaning compound of equal parts of powdered rosin, borax and flower of sulphur. Use a teaspoonful for a ten-pound melting and make sure the compound is perfectly dry.

Stir a little and if metal is at proper heat there will be a flare, flash or a little burning. A sort of tinfoil popcorn effect will be noticed floating on top of the metal. Stir until this melts down. Have your ladle hot and skim off soft particles. Dust the mould with mould compound, a powder which makes the lead fill the entire grooves, and not become cool before it does.

When everything is ready, fill the ladle and pour the lead into one of the grooves. Hold the ladle above one end of the groove while pouring, and do not move it along the groove. Fill the other grooves in a similar manner.

Post Builders. These are moulds which are set over the stumps of posts which have been drilled short in removing the inter-cell connectors.

Lead is then melted in with a burning flame to build the post up to the proper height. Figure 100 shows a set of post-builders, and Figure 101 ill.u.s.trates their use.

[Fig. 100 Set of post builders]

[Fig. 101 Ill.u.s.trating use of post builders]

EQUIPMENT FOR GENERAL WORK ON CONNECTORS AND TERMINALS

Moulds for Casting Inter-Cell Connectors, Terminals, Terminal Screws, Taper Lugs, Plate Straps, Etc.

Figure 102 shows a plate strap mould with which three straps and posts may be cast in one minute. It has a sliding movable tooth rack for casting an odd or even number of teeth on the strap.

[Fig. 102 Plate strap mould]

Figure 103 shows a Link Combination Mould which casts five inter-cell connectors for use on standard 7, 9, 11, 13 and 15 plate batteries, four end connectors (two Dodge tapers, and standard tapers, negative and positive), one end connector with 3/8 inch cable used on 12 volt Maxwell battery and on all other cars a wire cable, and one small wire to connect with end post on batteries requiring direct connection. It also casts two post support rings to fit standard size rubber covers and to fit posts cast with plate strap mould, and two washers which are often needed when installing needed when installing new or rental batteries.

[Fig. 103 and Fig. 104: Link combination mould, and castings made in it]

Figure 104 shows the parts which may be made with this mould.

[Fig. 105 Cell connector mould]

[Fig. 106 Production type strap mould]

Figure 105 shows a cell connector mould which casts practically all the cell connectors used on standard 7, 9, 11, 13 and 15 plate batteries. This mould is similar to the Link Combination Mould shown in Figure 103.

[Fig. 107 Indexing device for strap mould]

[Fig. 108 Castings made in strap mould]

Figure 106 shows a production type strap mould which is designed to be used by large battery shops. Forty-two styles of straps are, cast by this mould. This mould has an indexing device as shown in Figure 107, which is adjusted by means of a screw for moulding the straps for any number of plates from seven to nineteen. Figure 109 shows some of the castings which are made with this mould.

[Fig. 109 Terminal mould and castings made in it]

Figure 109 shows a Terminal Mould which casts five reversible end terminal connectors, a cable connector, such as is used on the Maxwell battery, and two washers often needed in making a tight connection.

[Fig. 110 Screw mould]

Figure 110 shows a Screw Mould which casts standard square lead leads on four screws in one operation, two 5/8 inch and two 3/8 inch. This mould has a screw adjustment in the base which makes each cavity adaptable to any length screw.

EQUIPMENT FOR WORK ON CASES

The acid proof asphaltum paint, paint brushes, wood chisels, wood plane, and earthenware jars are all standard articles.

[Fig. 111 Battery turntable]

Figure 111 shows a battery turntable which is very convenient when painting cases, lead burning, etc.

TOOLS FOR GENERAL WORK

Most of the articles in this list require no explanation. Some of them, however, are of special construction.

Separator Cutter. Some battery supply houses sell special separator cutters, but a large size photograph trimmer is entirely satisfactory.

[Fig. 112]

Fig. 112. Plate Press for Pressing Swollen, Bulged Negatives (After Plates Have Been Fully Charged)