Useless PSA lead battery clamps.

BX Tech talk
User avatar
DavidRutherford
BX Digit man!
Posts: 2706
Joined: Wed May 18, 2005 5:07 pm
Location: Placing comments on YouTube.

Useless PSA lead battery clamps.

Post by DavidRutherford »

... and how to bin them forever.

The standard lead battery clamps on almost all PSA vehicles are a waste of space. They cause problems with poor charging and poor starting, will stretch over time to come loose, and have been known to come off completely.

I hate them. If you do too, do this:

Image
The negative clamp on my BX was suffering from dissimilar metal corrosion from the steel bolt. It would come off the battery simply by sneezing nearby. It had to go.


Image
So you get one of these. It's a standard rubbish cheapo battery clamp from any motor factors (or dare I say it, even halfrauds) Note that the screws that normally clamp the cables have been removed (as this is the reason why they're normally rubbish.)


Image
Hack the old clamp off the cable. Not difficult since it's lead. Cut back about an inch of the insulation on the cable.


Image
My replacement clamp was a very cheap small one, and the hole for the cable wasn't big enough. This is it being drilled out.


Image
... and having a countersink put on the cable entry to make it easy to get the cable in.


Image
Cable inserted into clamp.

Now, I don't have photos of the next bit, so bear with me. You'll need a blowlamp, some plumbers flux and plumbers solder. Dip the ends of the cable in the plumbers flux and then assemble as the photo above. Now heat the clamp up until you can feed solder in through the holes vacated by the cable screws. Feed in solder until it drips out from somewhere, then allow to cool.

What you will then have is a nice soldered joint into a brass battery clamp. Way better than the PSA type.


Image
And that's the result. You can now do this clamp up tight without worrying about stretching it, or having the bolt/nut pull all the way through the clamp.

Note that I've used an M8 nut and bolt in this clamp. There's a good reason for that: the standard square-head bolt used on these clamps is a 1/4 Whitworth, which although I do have the correct spanner for, I don't carry one in my "emergency" toolkit. I do, however, carry a 13mm.

Having done this the engine cranked noticeably faster. I can only imagine how hot the terminal was getting during cold-starts.
this might be a signature
ellevie
Forum Treasurer
Posts: 657
Joined: Sat Jan 21, 2006 9:10 pm
Location: Southampton

Post by ellevie »

Nice David, that's worth remembering.

I'm always apprehensive about over-tightening the clamp nuts. I remember years ago I once thought I had completely ruined one of the clamps by over-tightening the nut, but then I realised that the battery terminal post is slightly tapered and that I wasn't pushing the clamp down enough.Since then, I always push the clamps down fully and tighten the nuts just to the point where I cant rotate the clamp about the terminal post. Touch wood, I've been lucky so far.
David

BX19TRS 118K E Reg 1992-2008
BX19TRS auto abs 96k F Reg
BX19TXD 150k K Reg
User avatar
m_2975
BXpert
Posts: 503
Joined: Mon Mar 27, 2006 12:08 pm
Location: Melbourne, Australia
My Cars: 1989 BX 19TRI Estate
1993 BX GTI
1997 Xantia CT Turbo

Post by m_2975 »

I wouldn't call the PSA battery connections the world's best invention by a long shot, but they are certainly nicer looking IMO, especially when they are new.

They can be a real piece of $h!t when the square headed bolt starts turning instead of staying like it should and the nut is would all the way in and it's still loose!

We normally remove the bolt and cut a small piece out of the middle to make it tighten and it always works.


Nevertheless, your idea looks really good. Brass connection, soldered cable, it's something very useful.

Thanks for the post

Michael
My Cars:
'93 BX 19GTi Sedan 5M
'89 BX 19TRI Estate 5M
'89 AX GT(With EFI) 2door 5M
In the Family:
'74 SM IE (Fully Restored) 5M
'90 BX 19TRI122 Sedan 4A
'02 Xantia Exclusive Sedan 4AA
'06 C5 2.2HDi Estate 6A
User avatar
docchevron
The Immoderate half of the admin team
Posts: 7524
Joined: Sun Jun 04, 2006 7:03 pm
Location: A Bucket of Fish
x 7

Post by docchevron »

Nice work mate!
Being bling I of course have GOLD terminals on mine.....
Smokes lots, because enough's enough already!

Far too many BX's, a bus, an ambulance a few trucks, not enough time and never enough cash...
Kitch
Over 2k
Posts: 6437
Joined: Sun Jul 03, 2005 9:36 pm
Location: Fareham, Hants
My Cars: Too many to list
x 94

Post by Kitch »

Did someone mention bling?

Image

Sorry....I know my battery wasn't bling enough, so it got replaced! :lol:
Kill Jester.
User avatar
MULLEY
Over 2k
Posts: 8406
Joined: Thu Jun 22, 2006 11:10 pm
Location: Derbyshire
My Cars: 1999 Xsara LX 2.0HDI (90) Hatch - Fern
2002 C5 2.0 HDI (110) Estate - Jasmine - SORN
2011 Mini Cooper D Clubman - SOLD
2016 Mercedes A180D Sport - Auto refinement
1992 TZD Turbo - Bluebell - SORN
1992 TZD Turbo Estate - SORN
1991 Gti 16V - Blaze - crash damaged, will get repaired - SORN
1990 Gti 8Valve SOLD - looks like it's been scrapped
2002 Mini Cooper S - SOLD - i miss this car
1992 TXD - Scrapped in March 2014
1988 CX 25 GTI Turbo2 - SORN
1996 - AX Memphis 1.5D - Dream - SORN
x 8

Post by MULLEY »

Whats that fancy red lead to the right of the battery (next to sphere)?
Kitch
Over 2k
Posts: 6437
Joined: Sun Jul 03, 2005 9:36 pm
Location: Fareham, Hants
My Cars: Too many to list
x 94

Post by Kitch »

Powers the amp in the boot
Kill Jester.
User avatar
MULLEY
Over 2k
Posts: 8406
Joined: Thu Jun 22, 2006 11:10 pm
Location: Derbyshire
My Cars: 1999 Xsara LX 2.0HDI (90) Hatch - Fern
2002 C5 2.0 HDI (110) Estate - Jasmine - SORN
2011 Mini Cooper D Clubman - SOLD
2016 Mercedes A180D Sport - Auto refinement
1992 TZD Turbo - Bluebell - SORN
1992 TZD Turbo Estate - SORN
1991 Gti 16V - Blaze - crash damaged, will get repaired - SORN
1990 Gti 8Valve SOLD - looks like it's been scrapped
2002 Mini Cooper S - SOLD - i miss this car
1992 TXD - Scrapped in March 2014
1988 CX 25 GTI Turbo2 - SORN
1996 - AX Memphis 1.5D - Dream - SORN
x 8

Post by MULLEY »

aha, must be bit of a beast then...
Kitch
Over 2k
Posts: 6437
Joined: Sun Jul 03, 2005 9:36 pm
Location: Fareham, Hants
My Cars: Too many to list
x 94

Post by Kitch »

Not really, that wires pretty thin by decent standards. :lol:
Kill Jester.
User avatar
m_2975
BXpert
Posts: 503
Joined: Mon Mar 27, 2006 12:08 pm
Location: Melbourne, Australia
My Cars: 1989 BX 19TRI Estate
1993 BX GTI
1997 Xantia CT Turbo

Post by m_2975 »

I've got one of those funny red wires too.

Mine's a bit thicker and powers a 4x150W power amp under the passenger seat. Nothing special really and I didn't really want it but I was told that I must have it (the wire that is!) :roll:

You can see the cable entering the cabin just behind the left of the battery and you can see the cable connected to the battery. The large fise is hidden behind the battery itself.

Image
My Cars:
'93 BX 19GTi Sedan 5M
'89 BX 19TRI Estate 5M
'89 AX GT(With EFI) 2door 5M
In the Family:
'74 SM IE (Fully Restored) 5M
'90 BX 19TRI122 Sedan 4A
'02 Xantia Exclusive Sedan 4AA
'06 C5 2.2HDi Estate 6A
User avatar
Mike E (uk)
1K Away
Posts: 1115
Joined: Sun Aug 14, 2005 9:10 am
Location: High Wycombe, Bucks
x 1

Post by Mike E (uk) »

I replaced my cable terminals too, but I used the quick release type with levers on so they can be removed instantly without any tools.

CPC.co.uk sell them.

I chose them after I had a starter solonoid fail short circuit.
la BX 16 soupapes: sachez apprecier avec moderation.



It might be clever now, but it won't be in the morning!
User avatar
docchevron
The Immoderate half of the admin team
Posts: 7524
Joined: Sun Jun 04, 2006 7:03 pm
Location: A Bucket of Fish
x 7

Post by docchevron »

Kitch wrote:Did someone mention bling?

Image

Sorry....I know my battery wasn't bling enough, so it got replaced! :lol:
Mine are a bit more bling, but similar, I'll take some piccies tomorrow, er, today.
M_29758767437543566574365874365 wrote:I've got one of those funny red wires too.
You also have two very random wires escaping from your engine bay!
Maybe powering the lights in the garage........
Smokes lots, because enough's enough already!

Far too many BX's, a bus, an ambulance a few trucks, not enough time and never enough cash...
User avatar
m_2975
BXpert
Posts: 503
Joined: Mon Mar 27, 2006 12:08 pm
Location: Melbourne, Australia
My Cars: 1989 BX 19TRI Estate
1993 BX GTI
1997 Xantia CT Turbo

Post by m_2975 »

docchevron1472 wrote: You also have two very random wires escaping from your engine bay!
Maybe powering the lights in the garage........
HAHAHA....No charging the not very "bling" battery that should be at the tip!

:lol: :lol: :lol: :lol:
My Cars:
'93 BX 19GTi Sedan 5M
'89 BX 19TRI Estate 5M
'89 AX GT(With EFI) 2door 5M
In the Family:
'74 SM IE (Fully Restored) 5M
'90 BX 19TRI122 Sedan 4A
'02 Xantia Exclusive Sedan 4AA
'06 C5 2.2HDi Estate 6A