Fri Mar 7 2008

Copper buss bars

During the week I read a post on Van's Air Force by Chad Jensen about polishing the firewall. I thought that was a neat idea, so I ordered a polishing kit. It'll be interesting to see how this comes out.

This evening I was feeling well enough to do some work down the shop. I laid out the locations of the two relays so I could fabricate the copper buss bars. The spacing between these posts needs to be 2 7/32, So I made the buss bars 3 inches long...a little longer than the plans called for.

Working with the copper was a real bitch. The drill bit kept grabbing. On top of that, this stuff gets hot. Even after drilling the holes, there's a lot of work because the copper's so soft it doesn't just form a actually mushrooms out the material all around the hole. So you've gotta do a bunch of filing just to get the pieces flat again.

Doesn't look like two hours worth of work, does it? Sigh.

The good news is the fit is perfect. Tomorrow I'll work on the mounting for these relays and the battery box.