I recently bought 16x280ah prismatic LifePo4 cells. The included terminal bus bars are not great. More importantly I only got 20 bus bars, so I can't top balance my cells. I looked for terminal bus bars on aliexpress - they were expensive, and shipping was slow. So I figured I could make my own bus bars, I looked into buying a copper bar and machining it into busbars, but I don't have the tools. Then I figured I could just use a battery cable with hydraulic crimped ring terminals. I like this idea because its easy to source the cable and terminals and I have access to a hydraulic crimper. What size cable should I use? based on an ampacity chart, I should use at least 1 AWG to get a 100 amps reliably to match the Ali Express bus bars. At a 1C discharge rate, I would have to use a 350 cable, and that just seems overkill. My main circuit has an 80 amp fuse, and I could probably program the BMS to close the discharge/charge relay at 80 amps too. In that case I could probably get away with 2 AWG bus bars.
Any recommendations?
Any recommendations?