Set the plates in a plate burning rack, as shown in Figure 96, placing the adjustable form around the lugs and strap as shown in this figure. Be sure to set the post straight, so that the covers will fit. A good thing is to try a cover over the post to see that the post is set up properly. The post must, of course, be perpendicular to the tops of the plates. If the slotted plate strap shown in Figure 5 is used, or if one or two plates have been cut off, melt the top of the lug of one of the plates which are to be burned oil, and the surfaces of the strap to which the plate is to be welded. Melt in lead from a burning-lead strip to bring the metal up flush with the surface of the strap. Proceed with each plate which is to be burned on.
If all the plates have been sawed from the strap, leaving the post with a short section of the strap attached, as shown in Figure 96, melt the edge of the strap, and the top of one or two of the end plate lugs and run in lead from the burning strip to make a good joint. Proceed in this way until all the lugs are joined to the strap and then run the flame over the top of the entire strap to make a smooth uniform weld. Be sure to have the lower edge of the strap fuse with the plate lugs and then run in lead to build the strap up to the proper thickness. Raise the flame occasionally to see that all parts are fusing thoroughly and to prevent too rapid heating.
When enough lead has been run in to build the strap tip to the correct thickness and the plate lugs are thoroughly fused with the strap, raise the flame straight up from the work. Allow the lead to "set" and then remove the adjustable form and lift the group from the burning rack. Turn the group up-side-down and examine the bottom of the strap for lead which ran down the lugs during the welding process. Cut off any such lead with a saw, as it may cause a short-circuit when the plates are meshed with the other group.
Post Building
In drilling down through the inter-cell connectors to separate them from the posts in opening a battery, the posts may be drilled too short. In reassembling the battery it is then necessary to build the posts up to their original height. This is done with the aid of post-builders, shown in Figure 100.
Clean the stub of the post thoroughly and also clean the inside of the post builder. Then set the post builder carefully over the stub post, so that the upper surface of the post builder is parallel to the upper surface of the plate strap. The built up post will then be perpendicular to the surface of the strap, which is necessary, in order to have the covers and connectors fit properly.
With the post builder set properly adjust the burning torch to get a sharp, hissing flame. Bring the flame straight down on the center of the post stub. When the center of the post stub begins to melt, move the flame outward with a circular motion until the whole top of the stub begins to melt. Then run in lead from a burning lead strip, Figure 101, at the same time keeping the flame moving around on the top of the post to insure a good weld. In this way build up the post until the lead comes up to the top of the post builder. Then lift the flame straight up from the post. Allow the lead to set, and then remove the post builder, grasping it with a pair of gas or combination pliers and turn the post builder around to loosen it.