Welding around batteries

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I checked in a while back and have been reading but not posting. In my retirement I got a 10hr a week job at the local golf course fixing carts. (Besides getting paid I get all the coffee, cold drinks and free golf I want) My question is this, about 75% of the carts are electric and have been poorly maintained. Many of the angle iron brackets that support the batteries have corroded away. I am going to weld new pieces in and I know the gas generated by the batteries can be explosive. How cautious do I have to be. Should I remove all six batteries? Most could be welded by just removing the center 2. Should I weld outside the building? There are about 40 in the building where my shop is and another 60 in the building next door. These are always on chargers which seems to generate more gas. Any ideas about cleaning prior to welding? Any and all suggestions welcome. Thanks
Reply:I always take the batteries out of vehicles when welding on them. The few minutes spent taking them out is well worth the safety IMO.John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:I have seen a few batteries blow up.  Take em out.  They generate hydrogen gas when charging.  That is what the Hindenburg was full of.  Remove the batteries.  Weld outside.  Just my opinionDavid  Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Yup, better safe than sorry.  As far as cleaning before welding, just make sure you get all the rust off.  The cleaner it is the better it'll weld.DewayneDixieland WeldingMM350PLincoln 100Some torchesOther misc. tools
Reply:Take the batteries out.  Sparks and heat from welding do not play nicely with batteries or the acid or hydrogen from the batteries.Remember that you can't weld things that aren't metal.  You can't weld rust, you can't weld paint, you can't weld corrosion or mill-scale, etc.  (for the picky, we aren't talking about 'welding' plastic together with a hot-air gun here!)For battery corrosion, I like to make a little paste of plain baking soda and some water.  Apply to the corroded area to neutralize any acid, then rinse well with water.  If you use HOT water to rinse, then it dries faster.  Dry well, then wire-brush and/or grind clean.  Clean crud off, and then you can start looking into the welding.
Reply:Originally Posted by David RI have seen a few batteries blow up.  Take em out.  They generate hydrogen gas when charging.  That is what the Hindenburg was full of.  Remove the batteries.  Weld outside.  Just my opinionDavid
Reply:Thanks for all the advice. I will be taking the batteries out and doing the job outside. I don't need another Hindenburg disaster. I kind of thought that would be the answer. Some of the corrosion is over an inch thick and really hard white crust. I had to use a pneumatic chisel to get most of it off. I'll try the baking soda and hot water then a knotted wire wheel and see how that works. Maybe I'll get some pics to post on Friday.
Reply:Saftey is reason enough to remove them. Add to that you'll never really know the extent of the damage until you get everything out of the way and take a look.
Reply:I had a car battery blow up in my face many years ago. I was connecting a battery charger and got a spark. Fifteen minutes of cold water in my eyes and I was OK again. The battery lost it's top. I have since learned to connect the ground cable remote from the battery. The sulfuric gives up Hydrogen when charging and we all remember the Hindenburg. Welding around batteries is a really bad idea.Miller Millermatic 252Miller Syncrowave 200Liincoln AC-DC 225Victor O-A Set