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Old 13-10-2013, 14:10   #1
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Extending battery switch posts?

Good day,

At some point in the past the 3 battery switches (house, start, both) were replaced on my boat. Because the new switches didn't match the holes for the old, the previous owner installed them over a covering piece of marine ply.

This pushed the switches further from the bulkhead, and as a result, the posts on the back of the switches are recessed quite deeply if you look at the from behind.

This has made getting cable terminals onto them very difficult, you almost have to bend the ring terminals 90 degrees to get them on.

Can anyone suggest a method of extending the posts? I'm thinking some sort of long nut with a threaded rod at one end. I need about 1.5 inches.

Cheers,

John
Nonsuch 30U
Tauranga, New Zealand


Something like these? What are these called?

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Old 13-10-2013, 17:44   #2
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Re: Extending battery switch posts?

Rather than covering the old holes with a piece of plywood is it possible to put the ply under the hole?

If you tidy up the old holes with a jigsaw, sandpaper and varnish it may not look too bad.

I would hesitate to use the extension nuts as the electrical connection may not be that good.
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Old 13-10-2013, 23:40   #3
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Re: Extending battery switch posts?

That switch is made by BEP, a part of the Mastervolt group. BEP is based in New Zealand & they have an amazingly helpful tech group.

The switch is one of their "Contour" group, a very clever series of switches. If you're re-wiring, have a look at their catalogue on line, it's a truly great resource.

BEP Marine Limited - The Marine Electrical and Electronic Specialists - BEP Marine
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Old 14-10-2013, 08:10   #4
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Re: Extending battery switch posts?

Greetings and welcome aboard the CF, petercoota.

John: "threaded rod couplings" (beware of dissimilar metals)
Threaded Rod Couplings - Grainger Industrial Supply
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Old 14-10-2013, 08:24   #5
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Re: Extending battery switch posts?

Do you have the space behind to surface mount them so only the switch face shows?

We have three of them mounted in a block with a VSR to form a square, since they slot together it allowed a much bigger cut out and avoided the need for 90 deg bends.

Pete
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Old 14-10-2013, 08:34   #6
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Re: Extending battery switch posts?

I have the same basic configuration using Blue Sea Systems switches. They look very similar to the BEP/Mastervolt unit in your picture. I was able to cut a round hole about 2-1/2 inches in diameter and mount the switches from behind the panel. Only the rotating handle protrudes above the surface and access from behind is greatly improved. Perhaps you could mount your switches the same?
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Old 15-10-2013, 13:44   #7
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Re: Extending battery switch posts?

I had no idea the switches could be surface-mounted (with the switch face at the bulkhead-face)...this would sove the problem, because it is the thickness of the doubled plywood that burys the posts at the back.

You've saved me the cost of these extensions...where should I mail the cheque?

John
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Old 15-10-2013, 14:23   #8
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Re: Extending battery switch posts?

There is a picture of our switches in the gallery.

Batt Sw - Cruisers & Sailing Photo Gallery

I tried, but couldn't make it show up in the post.
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Old 15-10-2013, 14:37   #9
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Re: Extending battery switch posts?

maybe this will work:
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