Stripped threads on aluminum cell

[Browneye]

I was thinking of making aluminum bus bars, but ended up just using the tin-copper ones Docan provided. Supposedly they are rated 230A. My bms is 120, I max out at under 100A.
No heating on test.
The group think talked me into replacing the main +/- lugs with tinned instead of copper. Copper on aluminum is about as bad as you can get.

The problem with aluminum is that it surface-oxidizes very quickly, which creates resistance. And corrodes quickly. It’s horrible in a marine environment.

 

[FilterGuy]

Loosely related to this thread: A couple of good videos talking about busbars and how important it is to have good connections:

Another Video from the same guy that mentioned having a washer between the cell and the lug

 

[Browneye]

Just don’t use zinc-plated washers - high resistance.
I replaced my balance leads terminals with SS washers, and tapped the bus bars instead of putting them under the terminal nuts.