Yup, another new idea I've had in mind for a while but didn't have the materials nor tools until now. Although I don't have a proper milling machine, I have been putting together a "mini" setup that should work quite well.
What the heck is it?
CUSTOM built solid aluminum battery terminals, ground blocks, power distribution blocks, wafer fuse holders... pretty much anything to do with vehicle wiring for power & ground wires.
Pics will come once I'm finished with my prototype for my truck, but these will be unlike ANY other battery terminal, etc you can find anywhere.
What makes them so special you ask??? They're custom built to YOUR specifications, not what some genius in (insert name of funny sounding foreign country here) who has no idea what you need or want.
I'm not even sure exactly what all I can do right now, my imagination hasn't caught up with my tools & materials yet. But, so far I'm working on positive & ground battery terminals for my Ranger to handle all of the wiring I currently have connected to my gold battery terminals along with a distribution block under the hood... all in one neat package.
My current setup:
Not bad, but I'm always looking for ways to improve on things.
Up next will be power & ground distribution blocks for use when running multiple amps. This will allow you to have a single ground point and have each of your amps ground wires running to a common ground that should help eliminate ground loop noises... plus I think it looks nicer to have all the wires bundled together. You can also run a single large gauge wire fused at the battery through the firewall to your amps where you can connect each amps power wires to a common power source.
Next in line will be my version of the super heavy wafer fuse holders. These are mostly used with large amplifier wiring or between the alternator & battery. I have a couple ideas in mind based on some pre-made fuse blocks I have now as well as my own ideas thrown in.
At some point I'd like to do some custom heavy duty ring terminals with my own twist... stay tuned for details.
I have a few ideas as to wire mounting options, but for now I'm going to be using holes with recesses and bolt type set screws and NO annoying clamping style attachment to the actual battery posts, rather carefully placed set screw bolts that will make a super secure connection that can easily be removed... if you have the proper wrench.
You'll want to make sure you inform the guy at your service place if you need to have the battery replaced as he'll have a heck of a time figuring out how to get the terminals off HA!
I also have ideas on mounting ring terminals to the blocks in various configurations... some configurations that I've never seen on any other terminals before.
I should be able to do these for wires as small as 12ga all the way up to 1/0ga wire. Smaller wires can be used and multiple small wires can be installed into the same location if you have several smaller wires that are too small for a single connection... for instance if you have two 18ga power wires for LED's, you can connect them both into the same connection.
Once again, these will be Custom Made to fit your needs.
If you need to attach one 1/0ga wire, two 4ga wires & five 8ga wires to a positive battery terminal, we'll come up with a design that incorporates them into the design.
If you need two 1/0ga wires attached to the ground terminal, we'll design something that works!
If you need a power or ground distribution block with 1/0ga input and seven 8ga outputs, we'll design something that works!
If you need to connect 2 pieces of 1/0ga wire together end to end (butt connector style) we can probably come up with something that will work too.
I say WE because we will need to work together to find dimensions that will accommodate your wiring needs yet is still something that can physically be done.
I'll be coming up with a chart of sorts with standard wire dimensions & the size openings they require so we can better determine how to layout your project. Once I know how many wires you have & the size of those wires, we can begin designing something to fit your needs. You will need to do some measuring for me as not every battery post location is exactly the same & I want to make sure we don't run into any interference with any of the hold downs, fill hole covers, etc.
The battery terminals will be designed around a standard battery type such as a Group 34 or 65 commonly used in Rangers. I'm using a Group 65 battery myself so that's what I'm building now.... but I should be able to accommodate the "high end" car audio style batteries that use attachment bolts rather than top posts. I should also be able to have options for side mount battery posts too.
The post mounting holes (Positive & Ground) on the batteries tend to be different sizes (Pos is usually larger than the Gnd) that are also tapered. I'm taking this into account when designing & machining them to have the best fit possible. I prefer to have the terminals to have a tight fit on the battery posts so you will be able to "adjust" the size of the posts to best fit the terminals using sandpaper, a file or a battery post cleaning tool.
As each will be custom, I'll have to do them on a "pre-paid" basis as the material is rather expensive, time consuming & truly one-of-a-kind.
The final finish of these projects will likely be either a machined finish or a hand finished "brushed aluminum" look. You could even paint them (just be sure to cover the areas where the wiring/terminals attach so you will have good electrical connections)
I may even try my hand at polishing them to a mirror shine... this will be a super high end option due to the extreme amount of time & effort polishing will require.
I'm also looking into ideas to add a little extra safety to them too.
Pricing is TBD
per each individual need, but per forum rules I have to have a price listed so..... I'll price them at $2,000,000.00 per terminal Or Best Offer.
I hope this idea is something everyone will benefit from... from the regular guy who just wants "a better mousetrap" to the guy looking for that extra special custom touch for an award winning system.
Check back often as I'll be posting pics & videos as well as new ideas as they come to me.