Teardown Of Dangerous Fake Wago Connectors

March 1, 2026 by Maya Posch 31 Comments

Everyone loves Wago connectors for how versatile and effective they are for quickly and securely connecting conductors, but it can be tempting to buy a bag of the significantly cheaper knock-offs. The reason why this can be a terrible idea is explained by [Big Clive] who tore down a few bags of them to ogle at their internals.

The main problem with some of these knock-offs is the way that they use the plastic molding as part of the structure that holds the conductors in place. Over time this plastic will develop larger tolerances, with heat developed from passing large currents speeding up the process. As the examined type of connector relies on metal clamps that securely push the conductor onto the busbar, having the plastic weaken, and the clamp correspondingly loosen up, is clearly not a desirable scenario.

As [Clive] says in the video, you’re probably okay using these cheapo knock-offs for a quick test on the bench, but you should never put them in a permanent installation. Not just due to potential fiery scenarios, but also for insurance claims should the worst come to pass, and the insurance company finds dodgy connectors everywhere in the electrical wiring. This isn’t the first we’ve heard of knock-off Wago problems.

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Battle Born LFP Battery Melts With New Problem

January 16, 2026 by Maya Posch 27 Comments

Following up on user-reported cases of Battle Born LiFePO4 batteries displaying very hot positive terminals, [Will Prowse] decided to buy a brand new one of these LFP batteries for some controlled cycle testing.

Starting with 30 cycles with a charging current of 49 A and a discharge current of 99 A, this put it well within the 100 A continuous rating for the battery. There is also a surge current rating of 200 A for thirty seconds, but that was not tested here.

What’s interesting about the results here is that instead of the positive terminal getting visibly discolored as with the previous cases that we reported on, [Will] saw severe thermal effects on the side of the negative terminal to the point where the plastic enclosure was deforming due to severe internal heating.

During testing, the first two charge-discharge cycles showed full capacity, but after that the measured capacity became extremely erratic until the battery kept disconnecting randomly. After letting the battery cool down and trying again with 80 A discharge current the negative terminal side of the enclosure began to melt, which was a good hint to stop testing. After this the battery also couldn’t be charged any more by [Will]’s equipment, probably due to the sketchy contact inside the battery.

It’s clear that the plastic spacer inside the terminal bus bar was once again the primary cause, starting a cascade which resulted in not only the enclosure beginning to char and melt, but with heat damage visible throughout the battery. Considering that the battery was used as specified, without pushing its limits, it seems clear that nobody should be using these batteries for anything until Battle Born fixes what appears to be the sketchiest terminal and bus bar design ever seen in a high-current battery.

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Born To Burn: The Battle Born LFP Battery

December 25, 2025 by Maya Posch 39 Comments

Would you feel confident in buying US-made LiFePO₄ (LFP) batteries? While the answer here is generally expected to be ‘yes’, especially compared to getting an unbranded LFP battery off eBay from a random seller, the outcome may not be that different. Case in point the 100 Ah, 12 VDC LFP Battle Born battery that [Will Prowse] took a look at to see why its positive terminal gets positively crispy.

Battle Born battery positive terminal. (Credit: Will Prowse, YouTube)

Once the lid was cut off, it’s easy to see what the problem is: the positive terminal is only loosely attached to the bus bar, leading to extremely poor contact. It also appears that there’s a plastic spacer which has properly melted already in this well-used battery that [Will] obtained from a viewer.

This overheating issue with Battle Born batteries has been reported for years now, which makes it a great idea to take a good look at any Battle Born LFP batteries you may have kicking around, as they may be plagued by the same design flaw. Trying to make use of the manufacturer’s warranty could be complicated based on the commentators in the DIY Solar Forum thread, as Battle Born likes to claim that the overheating issue is an external problem and not a design flaw.

Either way, it looks like an incredibly sketchy way to design a battery terminal on an LFP battery that is supposed to surge 100+A. [Will] is requesting that anyone affected posts details in the forum or similar to get all information together, as he looks to push Battle Born on this issue.

What makes this issue worse is that shortly after releasing that first video, Battle Born responded to some concerned customers with a response that claims that their terminal design is a ‘thermal fail-safe’, but as can be seen in [Will]’s follow-up video, it absolutely doesn’t look like one.

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The Lethal Danger Of Combining Welding And Brake Cleaner

December 17, 2025 by Maya Posch 57 Comments

With the availability of increasingly cheaper equipment, welding has become far more accessible these days. While this is definitely a plus, it also comes with the elephant-sized asterisk that as with any tool you absolutely must take into account basic safety precautions for yourself and others. This extends to the way you prepare metal for welding, with [Dr. Bernard], AKA [ChubbyEmu] recently joining forces with [styropyro] to highlight the risks of cleaning metal with brake cleaner prior to welding.

Much like with common household chemicals used for cleaning, such as bleach and ammonia, improper use of these can produce e.g. chlorine gas, which while harmful is generally not lethal. Things get much more serious with brake cleaner, containing tetrachloroethylene. As explained in the video, getting brake cleaner on a rusty part to clean it and then exposing it to the intensive energies of the welding process suffices to create phosgene.

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Fire Extinguishers, Optical Density Ratings And Safely Using Home Lasers

September 19, 2025 by Maya Posch 25 Comments

Ski goggle type laser safety lenses may look dorky, but they leave no gaps and fit around glasses. (Credit: FauxHammer, YouTube)

After [Ross] from FauxHammer miniature model fame got lured into reviewing laser engravers and similar via the Bambu Lab H2D’s laser module, he found himself getting slightly nervous about the whole ‘safety’ aspect of these lasers. After all, lasers can not only light stuff on fire, but it’s a well-known fact that even reflected laser light can be sufficient to cause permanent damage to your retinas. Or worse.

Since your eyes generally do not regenerate, it makes sense to get caught up on laser safety before turning on one of those plentiful-and-increasingly-affordable home laser systems for engraving and/or cutting.

While the issue of stuff catching on fire is readily solved by having a good CO2 extinguisher – and plan B options – at the ready, for safety glasses it’s significantly more complex. There’s not just the issue of finding glasses that block the wavelength of the laser system that you are using, but also with the right optical density (OD) rating. Every mm of the safety lens material can attenuate a certain amount of laser light at the given wavelength, so the OD rating of your laser safety goggles need to match the laser’s power output level, or you might be living with a false sense of security.

Finally, there is the issue of the smoke and fumes produced by these lasers as they obliterate the target material. Much of what is in this smoke you do not want to breathe in, even ignoring long-term dust and VOC exposure issues, so having a solid fume extraction setup and PPE as necessary are absolute necessities. As [Ross] puts it, you don’t want to breathe in the smell of regret today, for your future self to reflect on a decade from now.

Work safe, work smart, don’t become the subject of a laser safety PSA.

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Making Liquid Oxygen: Far From Easy But Worth The Effort

April 9, 2025 by Dan Maloney 26 Comments

Normally, videos over at The Signal Path channel on YouTube have a certain vibe, namely teardowns and deep dives into high-end test equipment for the microwave realm. And while we always love to see that kind of content, this hop into the world of cryogenics and liquid oxygen production shows that [Shahriar] has other interests, too.

Of course, to make liquid oxygen, one must first have oxygen. While it would be easy enough to get a tank of the stuff from a gas supplier, where’s the fun in that? So [Shahriar] started his quest with a cheap-ish off-the-shelf oxygen concentrator, one that uses the pressure-swing adsorption cycle we saw used to great effect with DIY O₂ concentrators in the early days of the pandemic. Although analysis of the machine’s output revealed it wasn’t quite as capable as advertised, it still put out enough reasonably pure oxygen for the job at hand.

The next step in making liquid oxygen is cooling it, and for that job [Shahriar] turned to the cryocooler from a superconducting RF filter, a toy we’re keen to see more about in the future. For now, he was able to harvest the Stirling-cycle cryocooler and rig it up in a test stand with ample forced-air cooling for the heat rejection end and a manifold to supply a constant flow of oxygen from the concentrator. Strategically placed diodes were used to monitor the temperature at the cold end, a technique we can’t recall seeing before. Once powered up, the cryocooler got down to the 77 Kelvin range quite quickly, and within an hour, [Shahriar] had at least a hundred milliliters of lovely pale blue fluid that passed all the usual tests.

While we’ve seen a few attempts to make liquid nitrogen before, this might be the first time we’ve seen anyone make liquid oxygen. Hats off to [Shahriar] for the effort.

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Why USB-C Splitters Can Cause Magic Smoke Release

April 7, 2025 by Maya Posch 41 Comments

Using USB for powering devices is wonderful, as it frees us from a tangle of incompatible barrel & TRS connectors, not to mention a veritable gaggle of proprietary power connectors. The unfortunate side-effect of this is that the obvious thing to do with power connectors is to introduce splitters, which can backfire horribly, especially since USB-C and USB Power Delivery (USB-PD) were introduced. The [Quiescent Current] channel on YouTube recently went over the ways in which these handy gadgets can literally turn your USB-powered devices into a smoldering pile of ashes.

Much like Qualcomm’s Quick Charge protocols, USB-PD negotiates higher voltages with the power supply, after which this same voltage will be provided to any device that’s tapped into the power supply lines of the USB connector. Since USB-C has now also taken over duties like analog audio jacks, this has increased the demand for splitters, but these introduce many risks. Unless you know how these splitters are wired inside, your spiffy smartphone may happily negotiate 20V that will subsequently fry a USB-powered speaker that was charging off the same splitter.

In the video only a resistor and LED were sacrificed to make the point, but in a real life scenario the damage probably would be significantly more expensive.

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