OK, so I forgot to take pics of the sanding process, but you can use your imagination to guess what they look like.
Here's what they turned out like after polishing... you'll have to forgive the dust & fingerprints on them I was in a hurry to get some pics done tonight.
One last little touch I did to the bottom of these terminals...
No reason to sand & polish the entire bottom of the terminals, so I did about 1/4" around all the edges then sprayed on a couple coats of paint.
The set screws for the wires are screwed in all the way in the pics, in use the heads will be about 1/8" to 3/16" above the terminals. I didn't want the heads to rub the top of the terminals & this gives a little more flexibility when using different size wires... in case he needs to run a 10ga wire in the 8ga hole, he will have a few extra threads to screw down to hold down the slightly smaller wire.
Like my set, I milled a chamfer into all the edges to relieve any sharp edges. I never like to leave sharp edges that can get bumped or scratched. Also kinda gives them a "lighter" or "thinner" feel even though they're a full 3/4" thick.
They'll get another final polishing before they're ready to ship out. The swirl marks came from the paper towel I used to wipe 'em down... note to self: use softer paper towel to prevent swirl marks.
All the screws have anti-seize applied & I found a simple way to include some dielectric grease to apply to the ends of the wires before clamping them down.
Just like my set, I gave them the battery pull test... I lightly tightened one of the terminals (before I polished them to prevent any scratches) to the battery post & I could easily pick that side of the battery off the floor by the terminal without so much as a wiggle from the terminal.
I'll be including some sandpaper with the terminals so he can fine tune his battery posts in the event his posts are a hair larger than the tapered openings in the terminals.
You can see how much shorter these are compared to my 1" thick terminals... but they work perfectly for the 4ga & 8ga openings.
I might be able to use this 3/4" stock for 1/0ga openings, but there may not be enough room for the recesses that hide the bare wires. I'll have to do some experimenting to see what I can come up with.
I'll be including a set of longer post set bolts if you want to use them for jumper cable hookups too.
For now, these are almost ready to send out.
Unfortunately I couldn't find any extra sets of allen wrenches to send along with these, but all 3 screw sizes are standard SAE sizes that most guys will already have in their toolboxes anyhow