Archive for December, 2009

Battery Interconnects

Wednesday, December 23rd, 2009

Well, the braided copper cable is cool and all that, but for the vast majority of connections, just plain copper bar is gonna be fine.  So I bought a whole bunch of pieces made to order at Industrial Metal Supply (very nice people, although you will need to go into the place to make special orders if you don’t have an account).  I also picked up the new license plates for the car.  Busy day (in addition to doing actual work).  🙂

Copper interconnects and the new license plates.

Copper interconnects and the new license plates.

Working on Battery Interconnects

Monday, December 14th, 2009

Well, due to the usual delays of business travel, pulled muscle, Thanksgiving and shopping for Christmas, not much was done until this weekend.

I was able to trim the battery boxes to a lower height – making a much better fit in the various compartments.  Apparently, the trick is to use a carbide blade with 60 to 80 bits in the power saw.  Worked great!

I also started working on the battery interconnects.  I’m looking into flat braided copper cable, with silver-solder for the ends.  However, I’m not happy with the way the ends have worked out – I don’t think they are flat enough yet.  This will take some tinkering to figure out.

Battery Interconnect sitting in the Silver Solder

Battery Interconnect sitting in the Silver Solder