Thread: Success, kinda!
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Old 08-14-2009, 02:06 PM   #15 (permalink)
MetroMPG
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Location: 1000 Islands, Ontario, Canada
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Blackfly - '98 Metro
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90 day: 67.07 mpg (US)

ForkenSwift - '92 Metro EV
90 day: 125.37 mpg (US)

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Another relatively low cost option for your cable ends (depending on strand size) is to tin them directly.

The majority of the 2/0 connections on the ForkenSwift were hammered relatively flat, then I wicked solder into them, making them solid. They were then ground flat & drilled for the battery post bolt.

DIY end top, OEM bottom:



I also tried the copper tube sheath approach, but it didn't work as easily:



For more info/details on how these were made, see starting around post # 406 in the ForkenSwift build thread, roughly here: http://ecomodder.com/forum/hreshowth...3-post763.html

Several years later, they're still working fine (not getting hot or flattening out/creeping).
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