We were initially unable to find the 90 degree terminal units shown in picture DSC01549.
DSC01549 of a commercial 90 degree terminal lug that is crimped to secure the 2/0 Copper stranded wire.
Initially, to obtain a terminal lug that allowed the 2/0 wires to exit vertically from the controller, I used 3/4" Copper hex bar stock and cut to length, drilled out one end with a 15/32" drill for the 2/0 stranded wire, then drilled and threaded the other end for a M8-1.25 stud. The terminal wire, when crimped (or Silver soldered) into the copper Hex, now exits the controller perpendicular to the controller housing. The other end of the 2/0 cable would need to be trial fitted, and that terminal lug crimped in the correct orientation so that there is not a kink in the wire itself.
DSC01582 The bottom of the image shows a 2/0 cable inserted into the hex bar stock. This cable can either be crimped or Silver soldered to place.
DSC01583 closeup view of the cut hex bar stock (McMaster 89985K927 at 12" for $98.15) with 15/32" drill and bevel (far left) for the 2/0 battery cable. The M8-1.25 with 13 mm depth terminal end for the stainless steel M8-1.25 x 25 mm stud (McMaster 93805A355, pack of 10 for $15.06). Far right shows fully assembled terminal lug.
DSC01581 showing the controller mounted on its side. This configuration might be used if the controller was attached to the car firewall or to the side of the motor compartment. If heat shrink tubing is used on these terminals, then there will be no exposed power voltages.
DSC01586 with added connections to the battery.
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