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I recently learned something and thought I'd pass it along for you guys. I had a salesman visit last week and point out the differences in pricing of Copper and Aluminum wiring. I hadn't really noticed as copper is the wire of choice in building construction because it's readily available and has a little less resistance for a given size. Lately though copper costs have gone sky high and the raw cost of copper is about 5X the price of aluminum! And aluminum weighs about a third what copper weighs. Just don't expect to save that large of a difference for aluminum but it is still much cheaper. 
I'm about to rework my ride with new Calb batteries. I'm also going to replace the copper from the pack to the controller and save a few pounds. 2/0 copper weighs .4lbs/foot. Aluminum weighs .12, about 30% the weight of copper.
I have about a 43' loop in my lead batteries so with that as an example if I were to use 2/0 wire the copper would weigh 17.2lbs. Aluminum would weigh 5.25 so I'd shave about 12 lbs. However for the aluminum to approximate the current ability of the copper you would need to increase the size by 1 and the weight savings would be a little less.
Reducing weight is like adding free mileage and there are a number of other things you can do.
Aluminum wire substitution is just something I've not read about here. Using my numbers I estimated the savings per pound at about .12 watts/pound. Below are links for weights for your own calculations and a link for amperage capacity comparison.
Ampacity table
Aluminum wire properties
Copper wire properties
I'm about to rework my ride with new Calb batteries. I'm also going to replace the copper from the pack to the controller and save a few pounds. 2/0 copper weighs .4lbs/foot. Aluminum weighs .12, about 30% the weight of copper.
I have about a 43' loop in my lead batteries so with that as an example if I were to use 2/0 wire the copper would weigh 17.2lbs. Aluminum would weigh 5.25 so I'd shave about 12 lbs. However for the aluminum to approximate the current ability of the copper you would need to increase the size by 1 and the weight savings would be a little less.
Reducing weight is like adding free mileage and there are a number of other things you can do.
Aluminum wire substitution is just something I've not read about here. Using my numbers I estimated the savings per pound at about .12 watts/pound. Below are links for weights for your own calculations and a link for amperage capacity comparison.
Ampacity table
Aluminum wire properties
Copper wire properties