Repairing Eveready Batteries
To properly open and re-assemble an Eveready battery, proceed as follows:
1. Take a hot putty knife and cut the compound from the top of each of the inter-cell connectors until the entire top of the connector is exposed.
2. Center punch tops of cell connectors and terminal posts.
3. Drill off cell connectors. In drilling off crescent cell connector use 1/2 inch drill, and for heavy type connector use 5/8 inch drill.
Drill deep enough, usually 3/8 to 1/2 inch, until a seam between connector and post is visible around lower edge of hole. Having drilled holes in both ends of connector, heat connector with soft flame until compound adhering to it becomes soft. Then take a 1/2 inch or 5/8 inch round iron or bolt, depending on connector to be removed, insert in one of the holes, and pry connector off with a side to side motion, being careful not to carry this motion so far as to jam connector into top of jar.
4. After connectors have been removed, steam and open the battery, as described on pages 332 to 335.
5. Examine plates, and handle them as described on pages 335 to 355. Remember, however, that Eveready plates which show the presence of large amounts of sulphate, even to the extent of being entirely covered with white sulphate, should not be discarded. A battery with such plates should be charged at the normal rate, and given a 50 percent overcharge.
6. Before re-assembling plate groups preparatory to assembling the battery, take negative and positive plate groups and build up the posts with the aid of a post builder to their original height.
Assemble groups in usual manner, taking care that posts on straps are in proper position relative to group in adjoining cell, so that cell connectors will span properly. Eveready batteries use a right and left hand strap for both positive and negatives, making it necessary to use only one length of cell connector.
7. After inserting assembled plate groups into battery in their proper relation as to polarity, heat rubber covers to make them fairly pliable and fit them over posts and into top of jar, pressing them down until they rest firmly on top of plate straps. See that covers are perfectly level and that vent tubes are perpendicular and all at same height above the plates.
8. Heat compound just hot enough so that it will flow. Pour first layer about one quarter inch thick, being careful to cover entire jar cover. Take a soft flame and seal compound around edges of jar and onto posts.
9. Now proceed to burn on top connectors. Cell connectors need only be cleaned in hole left by post, and top of each end.
10. While burning in cell connectors the first layer of compound will have cooled sufficiently to permit the second layer to be applied. This should be done immediately after burning on connectors and while they are still hot. Also heat the terminal posts, as compound will adhere to hot lead more readily than to cold.
Start second layer of compound by pouring it over cell connectors and terminal posts, first filling in with sufficient compound to bring level just above the tops of jars. Apply flame, sealing around edges of wood case, being particularly careful to properly seal terminal posts. Let this layer cool thoroughly before applying third layer.
11. The third layer of compound should be applied in the same way as second layer, pouring on connectors and terminal posts first, and filling in to the level of top of wood ease. The spaces between bars of cell connectors will fill and flow over properly if second layer has been allowed to cool and if cell connectors have not been burned up too high. In sealing last layer with flame, care should be taken not to play flame on compound too long as this hardens and burns the compound. Burned compound has no flexibility and will crack readily in service, thus causing the battery to become a “slopper.” In pouring compound be sure to have battery setting level so that compound will come up even on all edges of case. Do not move battery after pouring last layer until thoroughly cool.
Before installing battery on car be sure that no compound, etc., has been allowed to get onto taper of terminal post, as this will make a poor connection. If this has happened, clean with medium grade sandpaper.