I have 3 of the larger optima batteries that have the top post as well as
the side posts and I want to make custom Bus bars to go across the top and
connect the batteries to each other.

I am having trouble finding copper bars in the thickness I want, would
aluminium do the trick?

There will be one for POS and one for NEG and covers by a plexiglass cover I
made for the battery rack....

The bars will be about 2.25" wide x 1" tall x 21" long and have a hole
tapped in each end for a set scew and 0/1 guage wire and a few smaller holes
on the side for smaller wires for distribution...

Will aluminum work, has anyone here done this before? Also want this to
look nice as its on a truck I enter in shows some times.

I dont think aluminum is a very good conductor... (some one please
correct me if I am wrong).

I was working as a manufacturing process engineer in a plating / electro
polishing shop and some of the more difficult contracts involved
electropolishing, and welding aluminum. The stuff just doesn't conduct
electrons as readily as other metals. The 316 stainless jobs were a
piece of cake.

I think folks usually use brass or off the shelf zero gage wire for
that....???
Heres a 16" long piece of brass stock, that would work for 2 batteries,
perhaps the seller has longer ones available? Great thing about brass
is its soft and very easy to tap and drill.

http://cgi.ebay.com/ws/eBayISAPI.dll...m=2546109 707

Hope this helps

Garrett

smullen wrote:

I have 3 of the larger optima batteries that have the top post as well as
the side posts and I want to make custom Bus bars to go across the top and
connect the batteries to each other.

I am having trouble finding copper bars in the thickness I want, would
aluminium do the trick?

There will be one for POS and one for NEG and covers by a plexiglass cover I
made for the battery rack....

The bars will be about 2.25" wide x 1" tall x 21" long and have a hole
tapped in each end for a set scew and 0/1 guage wire and a few smaller holes
on the side for smaller wires for distribution...

Will aluminum work, has anyone here done this before? Also want this to
look nice as its on a truck I enter in shows some times.

Something like this... in Brass. Perhaps the seller would be willing to
cur a 26" long piece for a few more $$$. Metal shops usually charge by
the pound.

Does it have to be copper?
Garrett

http://cgi.ebay.com/ws/eBayISAPI.dll...m=2546220 709

smullen wrote:

I have 3 of the larger optima batteries that have the top post as well as
the side posts and I want to make custom Bus bars to go across the top and
connect the batteries to each other.

I am having trouble finding copper bars in the thickness I want, would
aluminium do the trick?

There will be one for POS and one for NEG and covers by a plexiglass cover I
made for the battery rack....

The bars will be about 2.25" wide x 1" tall x 21" long and have a hole
tapped in each end for a set scew and 0/1 guage wire and a few smaller holes
on the side for smaller wires for distribution...

Will aluminum work, has anyone here done this before? Also want this to
look nice as its on a truck I enter in shows some times.