Battleborn Battery Safety Issue

[jd1923]

11 hours ago, 2008RN said:

I updated my Truck to a 245Amp alternator with 4/0 to one battery and upgraded the link between batteries to 2/0.  I ran 1/0 back to the Oli for the Victron DC to DC charger.   While I was working with the big wires, I did the John Davies clean up in the battery compartment with 4/0 with smartshunt and shut off  switch  so that when I upgrade from AGM to Lithium I would have a good foundation. 

I bought a hydraulic crimper and I loved it.  Made all the work so much easier.  While I was at it I bought several extra lugs from 6ga to 4/0.  I love my dog but for me tools are mans best friend. They can make life so much easier, they just aren't warm and snuggly. 

You worked some great upgrades! Love your tool sentiment, but I'd be in trouble with Chris on the dog thing. 🤣

I've rewired all the important things in the Oliver, also added the DC-2-DC charger but using only 4 AWG. I understand a EE calculation calls for 2 AWG, and your a step better than that. I worked mine on a tighter budget, used the frame for the B- length of the truck, 65 ft total with a long-bed, and the design works well (less length, thinner wire). I also spent enough replacing the 130A OEM alternator with a US made, high quality 180A unit, thinking +50A was enough. I doubled the +/- connections from alternator to starter batteries by adding just 2 ft additional 6 AWG. (The main Oliver ground was only 6 AWG and I doubled that too.)

I get 35 Ah charging at idle with the 5.9 Cummins, numbers in the 40s when towing (highest reading 49A) with the Orion 50A. No issues ever with any of the cable and HW. Chris and I LOVE this upgrade. Five hours on the road will consistently provide over 200 Ah. In a 600 Ah system that's a 33% increase in SOC %, rain or shine! Ever get too low when boondocking, time to hit the road! 😎

Quality copper wire costs a fortune today. Sooooo high they are opening new copper mines in Arizona after many had closed decades ago!

My battery compartment is simpler than anybody's! I didn't want anything but batteries, 4/0 cables, insulation and tie-downs, nothing else (see before and after pics). What a mess OTT made of the battery bay, OMG. None of the extra 6 AWG wires were necessary. I cut off most of their length and attached them to interior buses.

For 45 years I have been servicing vehicles. Often the first thing I do is grab a 1/2" wrench and disconnect ground to battery. That's my shut-off. I understand in most use-cases a switch is handy, but our Oliver is 24x7x365 never in storage, only shut-off when working another mod. I also never turn off the inverter nor outside courtesy lights. The rooftop solar handles that.

I installed the shunt on the other end of the main 4/0 ground cable, attached directly to the inverter terminal with a shorty 4/0.

Back to the subject at hand...
For those replacing Battleborn batteries, it's a good time to upgrade the wiring and other electrical mods.

[CRM]

New Statement from BB. 

[rich.dev]

26 minutes ago, CRM said:

Statement from BB. 

 

Just more bla bla bla…when I read garbage generic responses like this I want to 🤮, the CEO’s coffee maker probably pulled this letter from their 10yo archives!

Why not own up to the fact their batteries have an issue, or at least come back with a something /video some explanation that makes sense to people that have more than 2 brain cells why Will Prowse, and btw Lithionics who called them out for same issues year ago, are taking too much kool aid! 

[2008RN]

1 hour ago, rich.dev said:

Why not own up to the fact their batteries have an issue, or at least come back with a something /video some explanation that makes sense to people that have more than 2 brain cells

Because it is easier and cheaper to deny and shift blame, and hope that a class action doesn't take place. This is the way the world has gone, no integrity.  I would bet the CEO is selling any shares if they even have them.  Sorry for the rant.

[rich.dev]

6 minutes ago, 2008RN said:

Because it is easier and cheaper to deny and shift blame, and hope that a class action doesn't take place.

I will be very surprised if a class action does not take place!  

[Mike and Carol]

9 hours ago, jd1923 said:

Back to the subject at hand...
For those replacing Battleborn batteries, it's a good time to upgrade the wiring and other electrical mods.

I’ve ordered my new Epoch 300aH batteries.  When we, @mountainoliver and I, did my upgrade from AGM’s to the Battle Borns, we also recabled everything so that like John, I have one red cable and one black cable in the battery box.  My Battle Borns are just over 5 years old.  I’ll keep them for a while as this Dragon Fly crisis progresses.  Mike

[topgun2]

2 hours ago, 2008RN said:

Because it is easier and cheaper to deny and shift blame, and hope that a class action doesn't take place.

 

2 hours ago, rich.dev said:

I will be very surprised if a class action does not take place!  

According to AI as of 2pm 2-12-2026

There is not an active, certified class-action lawsuit against Battle Born Batteries at this time, but a class-action lawsuit investigation is underway due to reported issues with overheating battery terminals. 

If you own Battle Born batteries, a survey has been circulating to gather information for the class action lawsuit investigation. 

 

Key Issues Under Investigation

The potential lawsuit stems from a reported design flaw in certain Battle Born battery models (specifically 12V, 100Ah, and potentially the GC2 models) where the positive terminal can overheat significantly during charging or under load. 

• Design Flaw: The positive terminal design is alleged to be problematic, with plastic isolating the terminal post from the busbars, forcing all current through a single aluminum bolt and nut. This can lead to the nut loosening, the plastic melting, and dangerous temperatures.
• Safety Concerns: Temperatures at the terminal have been reported to exceed 250°F (120°C), posing fire and burn hazards.
• Company Response: Battle Born Batteries (parent company Dragonfly Energy) has stated the terminal melting is an intentional "thermal failsafe" feature designed to prevent heat from reaching the internal cells in cases of misuse or improper installation.
• Warranty Issues: Some customers report that warranty claims related to these issues have been denied, which critics argue is contributing to the call for legal action. 

For potential claimants, industry experts and consumers on forums suggest:

• Checking the temperature of your battery's positive terminal under load using a temperature gun.
• Contacting the law firms conducting the investigation, whose information can be found through resources like the survey link mentioned in the search results.