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I'll keep an eye on them to see that it doesn't reoccur.
I have a theory as to what happened with this one. The bus bars aren't completely flat. They're like an inverted V, although only slightly, with the result that if you put them down on something that is perfectly flat, they would only touch said surface at either end with the center raised a bit. Torquing them down should force them to be flat.
Should. If it gets caught in the grove between the terminal and the nut around it, it won't spread flat. Or the torque on it was insufficient to make it spread out fully. Either way, it wasn't really in contact with the terminal itself. All the power had to flow through the aluminum nut around the terminal or through the bolt. And stainless steel is a lousy conductor compared to aluminum or copper.
I've re-torqued all the bolts. And, with the second half of my battery, I've bent the slight V out of the bus bars by hand. They sit flat even before the bolts are on, and don't try to get stuck in the gap between the terminal and it's nut.
I don't think it' something we need to figure out how to re-engineer. I don't expect it to be an issue again...unless a bolt come loose. In which case I'll deal with it then.
Thanks for the ideas. If I need them, I'll use them.
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