[Al Skierkiewicz]

OK Bud,
For the loosened terminals, I use and suggest a simple star lock washer(or internal or external lock washer) placed between the battery terminal and the wire terminal. I also use a star washer under the nut and screw head when screwing everthing together. The reduced surface area is more than made up for as the washer bites through surface oxidation, distributes the load on both terminals for a better connection and locks the joint together so it can't be turned.
As to the plates getting hot spots, I recently read an article that focused on post mortem battery failure of the AGM type battery. A few of it's advantages are thinner lead plates since the electrolyte is held tightly against the plate by the mat and less electrolyte due to the distribution of electrolyte ions being in such close proximity to the plates. All of this leads to a slightly lighter battery. Standard gell cell designs of a few years ago, in this battery size, were a pound or two heavier. The post mortem showed minute plate deformations that in some cases actually penetrated the mat and touched the opposing plate. Although the plates in the remainder of the cell were fine, the individual cell showed a reduced capacityor failed entirely. We use the West Mountain Radio, CBAII analyzer which will allow a varied load up to about 7.5 amps and will graph and calaculate the amp hr capacity. On several batteries, including some directly from the retailer, we found reduced cell capacity in only one or two cells. At discharge periods based on terminal voltage, we have recorded 2 volt drops far before the specified amp hr rating of the battery had been achieved. I published some of these graphs during the end of the 2006 season here on CD. I will include them in my presentation at the Championship as well. Following last year's season, other teams came forward with stories about reduced battery capacity in some of their batteries. I know this is far from a scientific investigation but it seems pretty widespread. I am just looking to gain a a running total of teams, drive trains and battery problems. Some teams have none, and we had only one infant death before last season.
As to the temperature strips, I think you will find that when properly applied, you will see significant case temperature rise, also based on particular drive train designs or multifunction robots. If you closely examine the case and the support structure on the top of the battery it is easy to see the individual cells. Mount the strip in the center of a cell rather than at the cell boundary and I think you will see the highest temperature rise. I have experienced elevated temps on several teams, a few to the point of case distension. It will be interesting to know what you find.