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DIY Aluminum Bus Bar

If you are fed up with too many wires running between batteries in your electrical circuits, then a bus bar (or "busbar") could be the solution. Busbars are pieces of conductive metal that are used to let a charge run between two points. Because metals like aluminum are already conductive, when you attach these metals to two batteries the metal gains a charge as it runs between batteries. To control this charge you just need to add contact connectors and wire connectors to an aluminum bar.

Things You'll Need

1 foot aluminum bar (1/4 inch thickness)
Permanent marker
Protective eye wear
Dust mask
Drill
Pilot bit
Final bit
Chop saw with abrasive blade
Vice grip
Dremel brush
4 3/8 inch bolts
2 3/8 inch nuts
2 3/8 inch washers
3/8 inch wrench

Instructions

Preparing the Bar
- 1
  Put on your protective eye wear and dust mask.
- 2
  Measure the distance between the points that you are connecting with the busbar. Add 2 inches to this measurement and write it down.
- 3
  Start from one end of your aluminum bar and measure out the length between your points. Mark this length with an X and draw a vertical line through the middle of it.
- 4
  Measure 1 1/2 inch from each end of your bar. Mark these points on the bar with an X.
- 5
  Mark another X 3 inches from each of your already marked points. There should now be 4 marks on your bar, two of which are 1 1/2 inches from the ends and two others that are 3 inches from each other and from the marks near the edges.
- 6
  Drill into the middle of each X with your pilot bit.
- 7
  Expand your holes with the 3/8 inch drill bit. After this drilling you should not be able to see any of the hole markers you had drawn.
- 8
  Put your bar in the vice grip and saw off the end of the bar beyond your measurement line.
- 9
  Run your dremel brush over your bar to dress it.
Completing the Bar
- 10
  Put your bolts through the two middle holes in your bar.
- 11
  Screw the nuts over these bolts using your wrench.
- 12
  Flip your bar so that the bolt heads are facing downwards (and the threaded sides are upwards).
- 13
  Place the two empty holes over the positive contact of one battery and the negative contact of another.
- 14
  Set your washers over the empty holes and place your bolts into these holes and use your hand to screw them in tightly.

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