We've been through the Cu vs Al many times here. Bottom line: More trouble than it's worth 
http://www.diyelectriccar.com/forums/showthread.php?t=48720&highlight=aluminum+cableMust have missed it. I've been a member about 3 years. What sort of problems since you brought it up?
So far I've quickly removed 43 lbs which I estimated should save about 5 watts/mile. When I rebuild the racks for the new batteries I'm making them much lighter as well. You can very quickly add a lot of weight overbuilding if you don't know the material strength and what it can support as was my case.Use the copper. Don't bother with a few lbs in a street vehicle. There are other things that can be done to strip a few lbs over going with aluminum. Unless your trying to gain that extra 1/100th of a second to your 1/4 mile time then it really does not matter.
I think you have heard that one before. A few tiny lbs on a street machine is no real big deal. At the drags it could be the difference between a win or loose.![]()
Cyclops, we use aluminum in building wiring in the USA all the time, usually in building the services and underground feeders. With the huge difference in copper and aluminum prices now it's going to be in more use unless copper prices decline. It can be used for interior wiring in the US BUT there are requirements just as there are with copper that must be adhered to for it to provide good service.There are very few standards in Aluminum, the way there is in USA electrical & plumbing copper.
There is a higher CONSISTANT QA in our building codes that require the 99.9 % purity of both trades.
Could be not so good anymore with world wide suppliers pushing out a USA only market. India, China & Africa come to mind. What else is new.
Haven't received them yet but I don't plan to do that. I may install some type ventilation at some point and use it to heat and cool. The Calb batteries have ribs on all sides and the bottom to allow air flow. If air is forced up from beneath it will spread and flow upward through the channels the ribs create.Electricar
Do you leave airspace between the cells in the center, to allow cooling during hot days & heavy loads on the batteries ?