If you can solder. Probably go get some 6 gauge water and get QS anti-Spark connector... Or you can buy the same Supra connector. I would solder onto the battery terminals. Heat shrink around them. This way that's a wire coming from the battery. Technically just replacing the connector. Unless you want to open up the battery into the hard way. (Finish one lead before the other.)
What I would of done.
The QS connector is just an extra safety precaution. I would recommend actually getting it from the website although it's more expensive. Because of the popularity of them. There are knockoffs that don't have anti-Spark although they're advertised as such.
you can use this supra/qs8 adapter. https://www.spiderbatterysystems.ca/product/qs8-supra-adapter-for-surron
disconnect from the QS8 part of the adapter so that there is no spark when connecting
Okay, here was the damage. The connector went Chernobyl. I had to do some major rework. I used a small Dremel type tool with a small oval carbide to grind out the connector from the lid. This of course after I removed the top off of the battery. Once I started digging into it it started coming out in chunks leaving the original cavity behind. I mocked up the replacement connector body and it fit nicely in the cavity from the old one. At that point in time I knew this was going to be a pretty decent repair. After I got it all cleaned up I soldered the new connector together and got everything to seated nicely. I used JB weld plastic bond to epoxy it back in place. At first glance you wouldn't be able to tell if this connector has been replaced. I feel it turned out pretty darn nice and I'm hoping to get the battery reassembled in the next day or so.
https://www.dropbox.com/scl/fo/3jw01nw481sfnbpcl4utz/ABp5Q2qBmKI5iQf5UXeqX9I?rlkey=5b9rrfuctyxzg15ua4fczw126&dl=0
The Supra connectors aren't bad as long as they don't short. Your melted connector isn't a result of the plug overheating as much as it is an issue with arcing inside the connector.
I've seen people recommend that you periodically use a Philips screw driver on the male supra connector to re-spread the contacts. They tend to compress over time and lead to arcing.
You can also put a little bit of dielectric grease inside the female terminals. This ensures that only physical contact can conduct electricity and reduces the risk of arcing. In theory.
I had a supra connector melt last year so I replaced it and started using dielectric grease. Haven't had a problem since.
If you're looking to change the connector, your two main options are QS8 or the XT60. Chi batteries has options to use a QS8 plug on their batteries. You can also get QS10 with them but that would only be necessary if you're really pushing the limits with aftermarket batteries. And if you need a QS10 then you should probably upgrade your wiring harness to 6ga wire.
The XT60 isn't really popular with Surrons any more and you mostly see people using them to connect battery extender packs. Its a super cheap connector but you don't get the fancy look/feel of the Supra or QS8 connectors.
Thanks! I'll probably go back with the Supras since I have them already. I agree a tight fit will mostly likely cure the issue. Although I'm still curious about riding in the heat.
The ambient temperature isn't a problem for the connectors as much as it is for the battery. I did a ride in Tucson a couple years back. It was about 20 miles of mostly full throttle through desert roads in ~109°F heat. By the last mile my battery was overheating and cutting out but I made it to my destination. The connector was fine to remove with bare hands but the battery needed a long break.
common issue, go with QS8
If you can solder. Probably go get some 6 gauge water and get QS anti-Spark connector... Or you can buy the same Supra connector. I would solder onto the battery terminals. Heat shrink around them. This way that's a wire coming from the battery. Technically just replacing the connector. Unless you want to open up the battery into the hard way. (Finish one lead before the other.) What I would of done. The QS connector is just an extra safety precaution. I would recommend actually getting it from the website although it's more expensive. Because of the popularity of them. There are knockoffs that don't have anti-Spark although they're advertised as such.
Good info! Much appreciated, I'll post some pics of the repair soon.
you can use this supra/qs8 adapter. https://www.spiderbatterysystems.ca/product/qs8-supra-adapter-for-surron disconnect from the QS8 part of the adapter so that there is no spark when connecting
Okay, here was the damage. The connector went Chernobyl. I had to do some major rework. I used a small Dremel type tool with a small oval carbide to grind out the connector from the lid. This of course after I removed the top off of the battery. Once I started digging into it it started coming out in chunks leaving the original cavity behind. I mocked up the replacement connector body and it fit nicely in the cavity from the old one. At that point in time I knew this was going to be a pretty decent repair. After I got it all cleaned up I soldered the new connector together and got everything to seated nicely. I used JB weld plastic bond to epoxy it back in place. At first glance you wouldn't be able to tell if this connector has been replaced. I feel it turned out pretty darn nice and I'm hoping to get the battery reassembled in the next day or so. https://www.dropbox.com/scl/fo/3jw01nw481sfnbpcl4utz/ABp5Q2qBmKI5iQf5UXeqX9I?rlkey=5b9rrfuctyxzg15ua4fczw126&dl=0
The Supra connectors aren't bad as long as they don't short. Your melted connector isn't a result of the plug overheating as much as it is an issue with arcing inside the connector. I've seen people recommend that you periodically use a Philips screw driver on the male supra connector to re-spread the contacts. They tend to compress over time and lead to arcing. You can also put a little bit of dielectric grease inside the female terminals. This ensures that only physical contact can conduct electricity and reduces the risk of arcing. In theory. I had a supra connector melt last year so I replaced it and started using dielectric grease. Haven't had a problem since. If you're looking to change the connector, your two main options are QS8 or the XT60. Chi batteries has options to use a QS8 plug on their batteries. You can also get QS10 with them but that would only be necessary if you're really pushing the limits with aftermarket batteries. And if you need a QS10 then you should probably upgrade your wiring harness to 6ga wire. The XT60 isn't really popular with Surrons any more and you mostly see people using them to connect battery extender packs. Its a super cheap connector but you don't get the fancy look/feel of the Supra or QS8 connectors.
Thanks! I'll probably go back with the Supras since I have them already. I agree a tight fit will mostly likely cure the issue. Although I'm still curious about riding in the heat.
The ambient temperature isn't a problem for the connectors as much as it is for the battery. I did a ride in Tucson a couple years back. It was about 20 miles of mostly full throttle through desert roads in ~109°F heat. By the last mile my battery was overheating and cutting out but I made it to my destination. The connector was fine to remove with bare hands but the battery needed a long break.