Cwah, I feel your pain. I had Anderson PP45s on my 48v system and they were holding just fine with minimal signs of wear. Then I upgraded my motor from a 500w to a 1200w and it set off a whole slew of new problems I wasn't experiencing before. Amongst them were melting/fusing PPs.
I had an SB50 (that came with a perfectly timed new battery I ordered), and while that lasted for a few months, it eventually started to drop the ball because the pins are pretty much the same concept as the poles. In that case, they were failing to touch.
I tried bullet connectors (the crimping type) and somehow, they were failing me within a week. Even though I had them connected and I heard that sweet sweet spark, it would just lose contact randomly during a ride. At first, I wasn't sure. It was almost ambiguous.
Now, I'm using spade connectors. They're not perfect either but they hold in really well and when they bug out, you're sure it's that and not something else. The only drawback is that you have to mind the gap on the male spade connector with some heat shrink because it eventually tend to leave a little metal exposed.
Hope that helps.
I had an SB50 (that came with a perfectly timed new battery I ordered), and while that lasted for a few months, it eventually started to drop the ball because the pins are pretty much the same concept as the poles. In that case, they were failing to touch.
I tried bullet connectors (the crimping type) and somehow, they were failing me within a week. Even though I had them connected and I heard that sweet sweet spark, it would just lose contact randomly during a ride. At first, I wasn't sure. It was almost ambiguous.
Now, I'm using spade connectors. They're not perfect either but they hold in really well and when they bug out, you're sure it's that and not something else. The only drawback is that you have to mind the gap on the male spade connector with some heat shrink because it eventually tend to leave a little metal exposed.
Hope that helps.