Originally Posted by 2fast4u
Question: How close can the battery terminals get to metal? Is an inch okay and should they be wrapped in rubber or something to make a barrier?
If you put the full rubber hoods over all battery terminals as you crimp on lugs you can go within an inch of racking, frame, hood, etc, and not worry.... remember that none of the high-voltage is grounded to the frame anyway, so there is little likelyhood of an arc unless you have BOTH pos and neg exposed too close to frame somewhere. The hoods on ALL terminals will protect you from accidental dropping of tools across terminals, etc. DO review cable routes to make sure that potential rub spots are held away from frame, encased in protective cover, etc.
I found that irrigation hose slips over 2/0 welding cable with a little ezglide, so I installed in a couple spots that could potentially wear from vibration.
I have some notes and such at http://envirokarma.org/ev/10.BattCables.shtml
and would advise that you buy or rent big crimpers rather than hammer-swedge the lugs...
and a series of pictures with some notes beginning w http://envirokarma.org/ev/gallery/09...5.complete.htm