separating the post from
the cover insert, the Willard Company furnishes special jigs and
forms. The work may also be done without these jigs and forms, as will
be described later.

When the special jigs and forms are used, the work is done, as follows:

1. Place Willard drill jig Z-72 (Fig. 279) over the connector, and
with a 13/16 inch drill, bore down far enough to release the connector
from the post (Fig. 279).

[Fig. 278 lead insert used on Willard Batteries; Fig. 279
Willard Drill Jig Z-72; Fig. 279 Willard Drill Jig Z-72 and
how it is used]

2. File off the post stub left by drilling. This will give a flat
surface on top of the cover insert and will make it easier to center
the drill for the next operation.

3. With a 57/64 inch drill, and Willard jig Z-94 (Fig. 280), drill
down to release the post from the cover insert.

[Fig. 280 Willard Jig Z-94; Fig. 281 Willard Post-Builder Z-93]

4. In reassembling, build the post up to a height of 1-5/16 inches
above the top of the plate strap, using Willard post builder Z-93
(Fig. 281).

5. After removing the post builder, bevel the top edge of the post
with a file, as indicated at "A" (Fig. 281). Then replace plates in
the jars.

6. File off tops of cover inserts at "A" (Fig. 282), to a height of
3/16 inch above the cover. Also remove any roughness on surface "B"
caused by pliers when cover was removed.

[Fig. 282 Willard Battery cross section of cover insert;
Fig. 283 Willard burning form Z-87 and how it is used]

7. Put on the covers so that their tops will be 1/32 inch above the
top edge of the jars, tapping them lightly with a small hammer.

8. Place Willard burning form Z-87 (Fig. 283) over the post and cover
insert and burn the post to the insert.

9. Remove form Z-87 and thoroughly brush off the top of the post stub.
Then build up the stub post, using Willard burning form Z-88 on the
positive posts and form Z-89 on the negative posts (Fig. 284).

[Fig. 284 Willard burning forms Z-88 and Z-89]

10. Now seal the covers with sealing compound as usual, and burn on
the connectors.

11. If the terminal posts are made for clamp terminals, build up the
posts by using Willard burning form Z-90, for the positive posts and
Z-91 for the negative posts (Fig. 285).

[Fig. 285 Willard burning forms Z-90 and Z-91]

To work on the post seals of Willard types SJWN and SJRN without the
special Willard jigs and forms:

1. Remove the conne