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http://thewireman.com/wire.html#tcb
offers one inch by .090 braided strap. This is the equivalent of
between 0 gauge and 00 gauge wire.
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| To
connect the copper strap to the batteries, we need to form 360 lugs.
Home Depot supplies us with ½ inch copper pipes. |
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These
have to be cut into ¾ inch sections. A pipe cutter gets the
job done fairly quickly.
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| Next
we improvise a quick strap measuring device … |
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| And
cut 180 2 inch straps. |
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A
battery pack is normally only as good as it's weakest battery. To
get the maximum out of our battery pack, we need to be able to easily
check individually, the state of each battery. To allow this, we are
going to include signal wires from each battery. To minimize wiring,
we will use a wire from each positive terminal only. By measuring
voltage from the positive wire of the first battery to the positive
of the second battery, we will get the voltage of the first battery
and it's connectors. Since this wire will be used for low amperage,
we can use a very fine gauge wire.
For $10, Home depot supplies a surplus roll of 1000 feet of Cat 3
Network wire. This is 3 sets of 24 gauge twisted pair wires. |
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|
We cut 35 15 foot lengths. Strip approximately a foot of the external
coating, and then 2 inches of each individual insulation. |
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| Now,
all the parts are ready. It is time to start production. Step 1, Insert
strap in tube… |
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| Then
use a drill press to crush the tube onto the strap. Half crush, adjust
strap, finish crush so copper pipe does not move easily. |
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| Insert
the other end of the strap into another bit of tubing (this is why
we need 360 tube pieces and only 180 straps). |
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| Half
crush tubing, adjust and insert signal wire fully (blue and white
wire on right). Some signal wire will stick out the back. Crush the
rest of the way. Signal wire should be secure for a gentle tug. |
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| Repeat
this six times until you have used all the signal wires in a bundle.
Next carefully lay out the six connectors on a metal block in a press.
None of the signal wires should cross another connector or even the
tube part of it's own connector. Otherwise the signal wire or it's
coating can be damaged. |
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| Using
another block of metal and a 20 ton Press, crush the copper tubing
onto the strapping. The goal is to "cold weld" the tubing
to the strapping. |
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| The
result are some very flat pieces. The signal wire does not pull out. |
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| Using
a drill press vice, we drilled six at a time (with a sacrificial piece
below to ensure a clean hole on the bottom lug). |
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| The
drill bit is 8 mm for the positive terminal. |
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Turn
the six around and use a 6 mm bit to drill the negative lug holes.
Simple,
Huh?
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