Last night while I was in bed about to go to sleep, I had a thought. The bolt I used to fix the battery clamp – I could machine the original bolt in the same manner. In this way, instead of buying a replacement stud bolt, I can end up with a bolt that does the same thing, slightly shorter than the original. I had fished out the end of the bolt that had broken off in the hole.
Here is the original bolt, with the broken piece at the end, and an identical bolt that I had used. By the way, those bolts came from a barbecue that was dismantled. I can turn down the original bolt and extend the thread so that I can put a nut on it to press down on the clamp. Ok – put the original stud bolt into my lathe, turn it down to 6mm diameter. Some of the corrosion came off – which appears to be battery acid corrosion. Then I put my hand crank onto the lathe spindle to manually turn the bolt, while I use a M6 die to cut the thread.
Here it is with the clamp assembled. Prior to installing it, I sprayed some white lithium grease onto the thread to protect it from corrosion and rust. We just have to check that it is tight – from time to time. This is my “review.IT” and “remake.IT” of the battery clamp stud bolt.
[NOTE] When working on the lathe, and on cars, it is quite remarkable that no matter how hard you try, you get grease on your hands. I use a “Tuff Stuff” hand cleaner that is fantastic at removing grease and grime, and keeps my hands soft and smooth – as it is non-abrasive. It has fine granulated polymer beads and has a fresh lime fragrance.