Thanks DaX.
Field tested the new cables/lugs today. 8 km, not even warm to the touch.
I don't think they'll be a problem.
Fourthbean: yes, some of the metal is missing now. It was just a glancing touch, fortunately.
--
Met up with Ivan tonight to start planning where to mount stuff under the hood. That means soon the controller will no longer be ratchet-strapped on top of a hunk of styrofoam on top of the transaxle!
I'll start with the controller, which will be mounted separately behind the driver's side headlight area, then we'll have to come up with some kind of a platform for the contactors, fuses, shunt, etc. Probably mount them over the transaxle.
The mounting criteria are: 1) don't block access to the front 2 batts, for easy removal; 2) don't obstruct the view of the motor (for show 'n' tell purposes only).
Of course the place with the most amount of room to easily mount all this stuff would violate both criteria.
Once this stuff is mounted and the wiring/cabling tidied up, I'm taking the ForkenSwift to the mechanic so we can get it licenced.