Cleaning Bus Bars and Nuts

I am working on the Gen 3 wire harness, it will be available in approx two months. I don't think I will be offering the harness for Prius C, and Camry at this time until the demand picks up. There is a lot of capital tied into this, and I need to make sure I can pay my bills before I can have something to reinvest in other products.

 

I noticed that bus bars on weak batteries oxidize fast on the module terminal side. The bus bars on a new OEM battery begin to oxidize after 3-5 years, depending on the climate, and begin to turn black on the module terminal side after 8-9 years. Based on this, I have the opinion that the bus bars begin to oxidize heavily along with loss of capacity.
When I tried to cut new bus bars, I was trying to find a thicker copper than OEM, but I was unable to find it in small quantities.
The new cut out bus bars oxidized in much the same way as those cleaned with vinegar, but on the module terminals they were clean. Thicker bus bars should be better able to withstand current loads and temperatures.

 

The health of the modules? In what way? Don't get me wrong. These busbars and harnesses are a great thing to help DIYers, but no one should be buying them thinking they are going to make the hybrid battery work any better than an OEM replacement harness. They'll be effectively equivalent and realistically the only "better" part may be pricing(?) Toyota OEM harnesses have proven themselves to last 15-20 years, even with some corrosion issues. Even though there's no reason to think they won't, only time will tell if these new harnesses perform as well.

 

@Kris_Parker

10% is 10% not sure why you say you only got $1 and change discount.

I just tested it with a shopping cart of about $180 and discount was about $18

 

Just trying to

I found there was an issue with how it was set up, I have addressed the issue, it should apply the discount correctly to all items.

 

Probably paid 9% sales tax which nets you 1% after the 10% discount.

Happens to me at Lowe’s and Home Depot with a 10% military discount plus sales tax. A recent purchase of $57.08 totaled $55.61.

 

No, as I mentioned, it was configured differently, but I changed it since. We do not charge tax for most of the locations.

 

I can confirm that.

I purchased 3 sets couple of weeks ago, it came on time, and VZvrtny gave me 10% discount after brief message and no sales tax when purchasing from his website..

I haven't had a chance installing them yet, but all seems to be good quality..

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It is important to note that the resistance cannot be measured with typical ohmmeter or multimeter. To effectively measure the resistance a 4-wire Kelvin based micro-ohmmeter must be used to separate pairs of leads for current supply and voltage measurement. Otherwise, the measurement, if can be detected, will be meaningless, or in the case of regular voltmeter, out of range.

 

Hi Guys & Gals. Is the corrosion not from the terminal stud rubber seals degrading over time and letting electrolyte seep out and wick through the wiring harness and eventually the battery ecu? seems like it's just a natural failure mechanism of the modules and anything you try to combat it will bear the same ugly result unless you can better seal the terminal studs?

Question I have always built packs dry and clean but would it be a bad idea to start using some type of electrical insulating spray or non conductive anti corrosion style lube carefully applied to buzz bars, voltage sensing plug & battery ecu, good idea or just messy?

I will be removing a failed pack from my daughter's 2008 this week which I rebuilt over Easter 2017 the bars were cleaned with battery acid and finished with steel wool, the sensing wires i just used steel wool no acid or vinegar ..

The car done 7 years and 140k km on that rebuilt cobbled together pack and it still actually has decent capacity! It failed with code P0AA6 526 - 612 a pretty good effort considering Kiwi told me this pack would be lucky to last 6 months! ..

Will be very interesting to see exactly how funky it is inside this one!

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