Title: 98. Discarded - copper tubing connections
I wanted short distances for all the main power connections, and certainly achieved it. On the firewall I have a vertical stack of the battery, my "fat wire point", the battery contactor and the battery bus. The total distance is 5 inches, and the longest segment is 2 inches. It is clumsy to have distances that short connected with cable and lugs. Consistent with advice in AeroConnection, I am connecting these parts with solid copper, formed from sections of copper tubing. The hydraulic crimper has multiple dies. Reversing a pair to get a flat surface, the 3/8 inch pipe is crushed to a flat of 14 mm x 1.2 mm = 16.8 square mm cross section. This is the same cross section as #5 AWG. which has a resistance of .00103/meter. 5 inches is .127 of a meter, so the length has resistance of .000156. Using an online calculator, at 14 volts it can carry better than 3000 amps while losing less than 1 volt. Yeah, I think it will work for my system. A headache in using solid copper is the alignment of the attach point - each of the 3 connections has ends perpendicular to each other. Cut it, crimp it, test fit, modify, test fit... there is no time savings here. Once fitted, cover with shrink tubing for some insulation - getting zapped is a PITA. A better approach might be to make the copper bar and put twists in it in order to get the alignment - I'll try that if I have any connection problems.


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