That's a small part of it, but not the biggie. Surface Contact Area, and Pressure is what is lacking to obtain 25 micro-ohm or less contact resistance. Additionally threading the holes in the copper buss compounds the problem because you cannot tighten a bolt tight enough to keep a terminal from slipping and making good electrical contact.
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If you strap the cables as they leave the bus bar and then tighten the bolts, that should help hold the tension.Leave a comment:
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You made two mistakes.
1. Should have made the bar two-hole connectors minimum.
2. The big mistake you can fix. Drill those threads outs and use regular 3/8-inch or 1/2-inch Bolts, Nuts, Washers, and Locking Hardware. You cannot get enough torque to hold a connector tight enough, especially using one-hole connectors. I would not need any tools to break off any connection you can make with your setup.
Never mind, just gofer it. You will learn later the hard way latter when connections fail.
Last edited by Sunking; 10-08-2018, 10:44 AM.Leave a comment:
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Looks Nice! What's the amperage you're planning to run through the system? Any reason you didn't just order a pre-made busbar? (just curious - I make stuff I can buy sometimes just for fun)Leave a comment:
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Copper Buss Bars
I made some copper buss bars for my battery bank today. They are made from 1 1/4" x 1/4" solid copper and right now I have stainless steel 8mm "studs" installed to attach 6 batteries and I machined some insulating standoffs from Delrin for mounting . The center stud is longer as I plan on the inverter, MPPT charge controller, and IOTA battery charger connected to be connected to that point. Batteries will be wired to the bars with equal length cable.
Buss bars 1.jpgBuss bars 2.jpg
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