Ran across this video on the EG4 Lifepower

[Mithril]

No these are not fine, and a 250A test for under 2 hours on a system that could have 600A capacity of battery without tripping BMS is not super convincing. Also, I've put in rivnuts in metal before, if you can pull them out with a normal handtool they were not installed correctly. If someone is using an impact gun on their busbar, well.... thats on them.

Regardless, that excessively large area that is steel means a lot of common cable ends won't have a good connection, and part of designing a sane DIY system/product is doing so in such a way other standard products work as expected.

 

[Bluedog225]

It’s issues like this where good customer service has meaning. Personally, I think it’s a bad design that should be fixed.

 

[Zwy]

I had to make a couple of new cables due to the 304Ah having the terminal post farther apart and snapped a photo of how I fasten the cables to the busbar using a stainless carriage bolt.



I can safely say I didn't have any problems with the carriage bolt pulling out of the busbar. The server rack cable tray holds the bolt from the backside so you can reattach a cable easily. As copper is soft, I just drilled a 5/16" hole, then used my shop press to cold head a square hole using a 5/16" steel carriage bolt. You want to push it in from the side you want the cable to attach to. Practice on some scrap copper first. Takes some filing on back side and the square hole.

 

[Mithril]

I had to make a couple of new cables due to the 304Ah having the terminal post farther apart and snapped a photo of how I fasten the cables to the busbar using a stainless carriage bolt. View attachment 139064

View attachment 139065

I can safely say I didn't have any problems with the carriage bolt pulling out of the busbar. The server rack cable tray holds the bolt from the backside so you can reattach a cable easily. As copper is soft, I just drilled a 5/16" hole, then used my shop press to cold head a square hole using a 5/16" steel carriage bolt. You want to push it in from the side you want the cable to attach to. Practice on some scrap copper first. Takes some filing on back side and the square hole.

If I was building a busbar I'd do something similar. Bolt from the back side with some method to keep it from spinning, keep as much of the copper intact as possible. IMHO any hole though a copper busbar should be 25% of the width at worse or less as well/

 

[timselectric]

Just laser weld the lug to the bus bar.
Problem solved.

 

[Mithril]

Just laser weld the lug to the bus bar.
Problem solved.

Can I borrow your laser welder? :D

 

[timselectric]

Can I borrow your laser welder? :D

I wish I had one. It would solve every connection issue.

 

[EastTexCowboy]

Just laser weld the lug to the bus bar.
Problem solved.

Ugh. Something else I have to buy now.