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Old 05-23-2010, 02:12 PM   #1
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2007 25' Classic
Port Angeles , Washington
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My BIG screw up...hole in battery.. HELP

This is embarrassing to the extreme.

I had installed 2 T-105's in my battery box. I was shimming the lid with aluminum flat stock. I was drilling the center hole in the hinge for the battery box lid/door. This idiot, that would be me, neglected to "personally" check to be sure that the drill bit wasn't going to go through and hit the battery.

Well, now there is a 1/8" hole in the top of the battery. It does go all the way through the top and I can see the acid through the hole. The hole is not near the posts.

My ego can never be repaired, but is there anything a guy can do to plug/fix the hole or do I replace this new $140 battery.

I think I completly ruined the reliability and perhaps safe use of the battery, but I thought I'd make a fool of myself and see if any of you folks had any ideas.

Thank you,


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Old 05-23-2010, 02:30 PM   #2
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Don't feel all that bad. 55 years ago I was asked to install an under dash radio in a brand new Mercedes. I was drill up under the dash and when I pulled the bit out my hand got wet. Mercedes used to mount the battery against the fire wall centered just above where I was mounting the radio.

I am sure you can find a tar that will seal the hole in you battery.

2004 Excursion 4x4
1991 34 ft. Excella +220,000 miles, new laminated flooring, new upholstery, new 3200 lbs axles

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Old 05-23-2010, 02:30 PM   #3
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1977 20' Argosy 20
northern valley , new jersey
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ouch, Dan!

however, if you've walked away from this with nothing more than a red face, I think you're good!

if you've missed the plates with the drill bit, the battery should survive OK. clean the top of the battery case with a little mineral spirits or alcohol, and hit the top of the hole with a dab of RTV silicone in whatever color is handy....

Joseph & Gabrielle

Simplicity is the ultimate sophistication - Leonardo da Vinci.

WBCCI 2087 - AIR 3144 - TAC-NJ2
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Old 05-23-2010, 02:34 PM   #4
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2006 22' International CCD
SAVANNAH , Georgia
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Been there Done that !!!!!!

Well I know you don't feel to confident right now but at least the hole is in the top of the battery so all the acid will stay put. I managed a hole in the bottom of a battery once. I junked that one but I think that a bit of sealer in the hole will take care of the problem this time.
Silicone sealer would work, but if you want to get fancy you could use a polyurathane sealer if you have time to let it cure--- some take days. I would not be worried about using the battery once the hole is repaired.
Good luck and be gentle on yourself, you can repair it-
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Old 05-23-2010, 02:59 PM   #5
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A big thanks to each of you for your input and understanding... trust me, you are far more understanding than I am right now.

I haven't decided to use it yet, but I found some stuff in my boat that might work???

It's a marine adhesive sealer used to put in screw holes and other fixtures below the waterline. My boat is fiberglass. In an emergency, it can also be used to help with a wet patch to keep your boat from going down. I have only used it with screws for things I have added to the boat... I have never had a leak.
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Old 05-23-2010, 03:01 PM   #6
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Perry , Florida
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Since the battery interior is vented to the atmosphere, I agree that the silicone pluging should work if'n the plates were not damaged. Down side is that you've probably voided the warrenty.
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Old 05-23-2010, 03:03 PM   #7
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Kiln , Mississippi
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Go to the hardware store and get a nylon or plastic screw, made like sheet metal screws for marine use. Dab some silicone on it for safety and screw it in the hole - it will not pop back out and will give you a level of confidence that it will stay put bouncing down the road.

Once witnessed a guy drill a hole through small piece of wood into his knee cap. Now that was a sight to see. Battery, no big issue, move on.
Michael & Tina with Layla and Preston BZ
The family has grown.
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Old 05-23-2010, 03:34 PM   #8
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JB Weld, the magic cure for just about anything.
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Old 05-23-2010, 03:35 PM   #9
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Lexington , Minnesota
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Any drill mishaps that don't involve blood and body parts is not worth losing too much sleep over. That's a pretty simple oppsy and easy enough to fix.

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Old 05-23-2010, 04:54 PM   #10
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1962 22' Flying Cloud
Bend , Oregon
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I see a great start to a "things Iv'e accidentally drilled a hole through" thread here! Let's not be shy now! My personal best was a dead center hit on a pex line, full of water of course! I knew the line was near where I was drilling but thought..what are the odds? 100% it turns out!
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Old 05-23-2010, 05:15 PM   #11
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1993 21' Sovereign
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The fix for this (you're not the only one) is to clean the area, and put a dab of hot glue over the hole. That's what the battery warehouse I used to work at did when a battery was holed. The hot glue they use is slightly different from what you find in a craft shop, though.
Meddle not in the affairs of dragons, for you are crunchy, and taste good with ketchup.
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Old 05-23-2010, 06:28 PM   #12
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Morada , California
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the battery cases are made from a polypropylene material, and it's hard to get anything to 'stick' to it...

In our battery shop, we've tried for years to fix holes or cracks below the battery fluid level, but to no avail...there is a way to 'weld' the plastic back together, but you have to drain the battery to attempt this kind of repair - a nasty situation!

Just about any of the above mentioned repairs for a small hole in the case cover should fix you up...I've used the hot melt glue gun for this kind of repair many times - if any glue drops inside, it will just rest on the top of the plates and cause no damage...

I've also used JB Weld type of epoxy, as it will stay in a 'blob' and not run into the hole or crack...I still prefer the hot melt glue, however...even if you don't have the 'gun' you can melt a blob from the glue stick with an open flame (WARNING - don't get an open flame close to the battery vents and any possible Hydrogen gas that may be present!!!!!) and form it into the hole with a flat stick or screw driver...

Ray & Pat; Morada, CA
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Old 05-23-2010, 08:10 PM   #13
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J-B Weld?
Michelle TAC MT-0
Sarah, Snowball

Looking for a 1962 Flying Cloud

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Old 05-23-2010, 08:22 PM   #14
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Port Angeles , Washington
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I don't know the words to accurately describe how much I appreciate your time, guidance and wit on all of this.

I liked all of the suggestions, but the one product that I already had that didn't require me to drive all the way to town was J-B Weld. It seems to have worked. Of course after it sets up, I will put a sticker over the "gaping crater" to hide the evidence of my crime.

So, my day no longer sucks and all is nearly right with my world again. After I finished the project , my bride told me that I had the swagger back in my walk, so it looks like I'm going to survive this moment of horror.



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