How to fix a duff battery!

I used to make my own lead acid batteries when I was a kid. I used old scrap lead to cast the plates using a large ladle over the kitchen gas cooker and then cast the plates using a mold knocked up out of some bits of wood. I diluted the acid myself from fuming Sulphuric acid and the plates were bound together with cable ties with rubber insulators cut from an old car inner tube. The battery cases were old glass coffee jars with each jar being a single 2.1V with two plates cell.

However, Stu's video is that done large. :ambivalence:

Actually, just remembered not cable ties because they hadn't been invented but rubber bands cut from the same inner tube!

Richard
 
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Just makes you realise there's nothing complicated in a lead acid battery. Just lead plates and sulphuric acid. It's worth rebuilding one in Pakistan because labour is cheap (and there's no inconvenient safety regulations).
 
Just makes you realise there's nothing complicated in a lead acid battery. Just lead plates and sulphuric acid. It's worth rebuilding one in Pakistan because labour is cheap (and there's no inconvenient safety regulations).

Given the lack of respirators I think those men lung damage, and from handling lead they will only have a few years at work before they suffer kidney damage from lead poisoning.
 
Brilliant video.
In the aircraft industry, in the 70's, a common practice to revive batteries was to drain the sulphuric acid, flush them, check the plates for distortion, condition etc, fill them with acid and charge them at a very low rate for 4 to 5 days. Then carry out a series of tests over a seven days period. Very few batteries failed the tests.
 
Fascinating video. Back in around 1966 there was a company near Perth that did just that on a commercial scale in a small factory. I guess they disappeared from OH and S concerns and competition from new battery makers. I presume from the video he was using new plates. Presumably cast from lead. Also new separators from plastic. Or can you use old separators. Some of these 3 rd world country people can be very ingenious in their vehicle maintenance. ol'will
 
I'm busy collecting lead for the yacht I'm building. I've just about got it all but I was given a very large truck battery so I decided to melt it down. Amazingly (through trial and error) I dismantled the battery the same way as he did but it took me half a day not a couple of minutes as he did in the clip.

I waited for a strong wind to blow the fumes away from my property but the lead would not melt. (I finished up with a whole lot of very heavy gravel like material)
 
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