PV Gap

Diana Said:

I seek to build deep-cycle batteries.?

We Answered:

I'd reccomend against this, there are a myriad of dangers dealing with molten metal and especially lead. I've known people that work in battery factories (interstate) and they tell some ugly stories, it takes very little lead (and even less lead fumes) to do alot of damage.

As far as creating your own alloys this is fairly foolish as well. The main killer for batteries is corrosion and failure of the lead plates. However careful you think you are you will never get the same quality and workmanship as a large manufacturer using modern tools and methods.

Look into industrial deep cycle batteries, they have lives projected at 10-20 years with good practices, your PV panels are probably only going to work for 25 years so its a decent match. You can buy some serious batteries for a couple thousand, imagine your solar sells are going to set you back more than that

If you are crazy enough to want to make your own then melt it in a very open area, wearing a respirator with the wind going at your back. You want the plates as thick and uniform as possible. You will never get a good pour by hand but if that is what you want, that's the only way to do it.

As far as re-using lead oxide I'm not sure you need to. Lead is pretty cheap, just buy some new lead. The old lead can be re-melted, its not going to all be PbO, just melt it and take the slag (oxide) floating on the top.

I hope you don't create a big environmental issue on yourself or your property, I'm sure you will spill and contaminate everything with the fumes.