You are sitting beside your home, bed, kitchen, protection, transportation, and expedition vehicle all rolled into one, on a remote beach in the Baja. You hear a sizzling sound coming from the engine compartment. The truck has been parked for at least day. Hmm. You open the hood and take a look around. After a short inspection, you see a pile of white crystals around one of your battery trays. Hmm again, with a bit of uh-oh. You disconnect the ground lead, and the sizzling stops. Another look reveals the battery tie-down bolt has vibrated off. You've got a hole in your car battery; apparently washboard roads ARE good for something.
This happened to us - and like many places on the Baja, there was nobody around, and a walk would have taken far too long. This is how we got our truck going again.
...it's a true story, and was one of many that were less than ideal...
Let me preface this with a little "don't try this at home." What we had to do was dangerous and definitely a last resort. When you're all alone you have to be creative, but you must never sacrifice your safety. Remember expedition travel can be dangerous, and requires all of your wits and guts about you.
The Fix
Battery plastic can be welded (melted) together. Here we describe how to weld the battery hole closed.
If you have the handle to your battery, chances are it's the same type or at least compatible plastic with the battery case. The handle serves as your welding rod. We always have propane and a small torch tip with us in our box of tools, so we figured we would be able to weld up the hole.
Batteries produce hydrogen gas. Hydrogen gas is very explosive, and this is what makes the fix so dangerous. Blowing a battery up is bad for the battery, but if you're anywhere near it you can get sulphuric acid on you, which can result in serious chemical burns. The following points describe the safest way to fix a hole in your battery:
- Wear protective clothing. Put on pants, long sleeves, and find some glasses or something to protect your eyes. Wear gloves.
- Place the battery on the ground, with the hole facing up. Place a board or something between you and the hole, leaving just enough room so you can reach around and see what you are doing.
- Clean and dry the battery around the hole with a rag.
- Cut a piece of the plastic handle that is just larger than the hole.
- Heat up the donor piece so that it is melted on the side that will go against the battery.
- While the plastic is still hot and melted, place it over the hole. It will partially bond with the battery.
- Now comes the dangerous part: you have to complete the bond. Do this by taking a section of the handle and melting the end. Quickly, lightly feather the battery around the edges of the donor piece to heat up the area. Dab the heated area with the melted handle end. You have to go back and forth a bit to keep the handle section melted, while keeping the battery plastic just hot. During this stage you run a serious risk of igniting hydrogen gas, blowing up the battery, and burning yourself.
- Once you are satisfied that the hole is closed, turn off the torch and turn the battery right side up. If it's not a sealed unit, fill it up with water. Replace it in the vehicle, cross your fingers, and hope that it starts.
That's it. This fix worked for us - it's a true story, and was one of many that were less than ideal. However, it got us running again, and as soon as we came to a town with supplies we replaced the battery with a new one.
You are lucky you did not get injured using your over complicated and dangerouse method.
All you needed was one of the epoxy putties that you can buy at hardeware store and some duct tape. When going on an expidition, arange of glues and epoxies is essential.
Brian, we’d have to agree – it was dangerous and we were lucky. Your suggestion is a good one.
My 12V lawnmower seems to have just one low cell. I have had it on a charger (low setting) for about 2 days and the cell will now charge up. All the others are OK. Is there any good method of bringing the bad cell back to life? Thanks, Rich
is this guy a mental case? lucky the battery didn’t
blow up in his face . .. couldn’t 10 wraps around with duct tape have done the trick? oh ya, I know
someone who lost an eye sticking a lighter in a battery hole . .when the battery blew up
I used this information to fix a hole in my battery case. I also revived the battery at the same time . I drained the acid flushed the battery with rain water. then welded the case using a propane torch, which took several tries. After filling in the hole I used a solution of 1 cup rain water to 1 cup epsom salt (also known as magnesium sulfate) filled the battery and trickle charged. works fine.
My son had a huge hole in the top of his battery, he “not knowing” wired a sub box in his truck and did not put a fuse in the line. Of course the wire “when it got grounded” melted off of the battery itself and was so hot that it actually burned a huge hole “about 1/2″ by 2.5″ long on the top of his NEW battery!
What worked for me %100 is;
First, I took the battery off of the vehicle, “did not have to drain the battery, this fix was done with acid still in the battery”
I then broke off the battery handle and cut off a piece about the size of the hole, I melted the battery handle slowly using a heat gun “soldering gun” to get it to stick in place, then I moved up to a torch and a big screw driver. Constantly heating the screw driver tip with the torch I slowly molded the plastic handle to the top of the battery “do not put the torch close to the battery” eventually closing the hole, and this makes a VERY GOOD finish job.
IMPORTANT NOTE: Do not overheat “such as actually pointing the torch on the battery” as the handle patch / piece with slowly turn into a goo / liquid and will melt down in the battery and you will have to start all over again! “you learn by your mistakes!”.
THIS FIX WORKS, YOU DO NOT HAVE TO READ ANY FURTHER FOR ANY KIND OF MONKEY FIX.
I PROMISE YOU WILL NOT REGRET TRYING THIS FIX.
PS: Do not rush this fix, take your time to do it well.
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I want to repair my 6 volt repo “FORD” script battery, It is Tar covered on top, but has a crack from anode out. I was going to melt some roof type tar and pour into the cracks that I have “V’d” out. Not draining the acid out. Not open flame, I will use a hot plate to melt the tar. My battery has a tar top. Think it will work?
I put the wront e-mail address the first should d. (to wit dalesmith36@charter.net) oops.
I love what you guys tend to be up too. This kind of clever work and
reporting! Keep up the wonderful works guys I’ve incorporated you guys to blogroll.