Burning on the Cell Connectors and Terminals

Have the posts perfectly clean and free from acid. Clean the tops,
bottoms and sides of the connectors with a wire brush, Figure 143.
Finish the top surfaces with a coarse file, Figure 144. With a pocket
knife clean the inside surfaces of the connector holes. Place the
connectors and terminals in their proper positions on the posts, and
with a short length of a two by two, two by one, or two by four wood
pound them snugly in position, Figure 145. Be sure that the connectors
are perfectly level and that the connectors are in the correct
position as required on the car on which the battery is to be used.
The top of the post should not come flush with the top of the
connector. Note, from Figure 146, that the connector has a double
taper, and that the lower tapered surface is not welded to the post.
If the post has been built up too high it should be cut down with a
pair of end cutting nippers so that the entire length of the upper
taper in the connector is in plain sight when the connector is put in
position on the post. This is shown in Figure 146. With the connectors
in place, and before welding them to the posts, measure the voltage of
the whole battery to be sure that the cells are properly connected, as
shown by the voltage reading being equal to two times the number of
cells. If one cell has been reversed, as shown by a lower voltage
reading now is the time to correct the mistake.

[Fig. 143 Brushing connector before burning in]

[Fig. 144 Rasping connector before burning in]

The connectors and terminals are now ready to be welded to the posts.
Before bringing any flame near the battery be sure that you have blown
out any gas which may have collected under the covers. Then cover the
vents with asbestos or a wet cloth as already described. You will
need strips of burning lead, such as those made in the burning lead
mould described on page 164.

Use a hot, hissing flame for the first stage. With the flame properly
adjusted, hold it straight above the post, and do not run it across
the top of the battery. Now bring the flame straight down over the
center of the post, holding it so that the end of the inner cone of
the flame is a short distance above the post. When the center of the
post begins to melt, move the flame outward with a circular motion to
gradually melt the whole top of the post, and to melt the inner
surface of the hole in the connector. Then bring the