Looking through the Galco website at the various flexible buss bars they offer, I came across this:
It's a multilayer, flexible, insulated, tinned copper bar. Prices vary with the Amp capacity but for $50-70 you get 2 meters with a 200A rating. You might get 20-30 buss bars for that. It can be cut with shears, terminal holes made with a punch or a drill, and it can also be bent, twisted and otherwise shaped to fit any unusual configurations. Granted that cutting the insulation off for the area to be punched is probably fiddly but I would guess its still easier than the alternative methods I've seen and tried.
It's a European product and so has both very comprehensive testing data and a dizzying array of matching components and tools. The tools are insanely expensive and I'm sure out of range for most of us, especially for someone needing only a small lot. Though maybe the manual insulation cutting knife would be worth it. However it does sound like it's easy to work with using conventional tools. Not sure if there is enough flexibility in the material itself over a short run between battery terminals but simple to stamp a curve into the middle. And because of the flexibility it would not require super high precision hole spacing or length.
I've ordered some and will experiment. I'm also thinking that this could replace heavy wire for the battery wires. Set one end, bend and shape the bar to the destination terminal and punch a hole in that end.... No trying to force heavy wire into bends and odd spaces, no terminals or crimping tools needed, no stressed crimp joints and a nice flat connecter to work around. I'll report back once I've tried it.
Galco
galco.com
It's a multilayer, flexible, insulated, tinned copper bar. Prices vary with the Amp capacity but for $50-70 you get 2 meters with a 200A rating. You might get 20-30 buss bars for that. It can be cut with shears, terminal holes made with a punch or a drill, and it can also be bent, twisted and otherwise shaped to fit any unusual configurations. Granted that cutting the insulation off for the area to be punched is probably fiddly but I would guess its still easier than the alternative methods I've seen and tried.
It's a European product and so has both very comprehensive testing data and a dizzying array of matching components and tools. The tools are insanely expensive and I'm sure out of range for most of us, especially for someone needing only a small lot. Though maybe the manual insulation cutting knife would be worth it. However it does sound like it's easy to work with using conventional tools. Not sure if there is enough flexibility in the material itself over a short run between battery terminals but simple to stamp a curve into the middle. And because of the flexibility it would not require super high precision hole spacing or length.
I've ordered some and will experiment. I'm also thinking that this could replace heavy wire for the battery wires. Set one end, bend and shape the bar to the destination terminal and punch a hole in that end.... No trying to force heavy wire into bends and odd spaces, no terminals or crimping tools needed, no stressed crimp joints and a nice flat connecter to work around. I'll report back once I've tried it.