[jhornbr225]

I decided to just go ahead and drill holes and mount aluminum plates.

It takes some time, as all the parts are custom. To fit 10-32 nuts under the humps, I have to file them down to be narrow, and then put a 45° on each side. The nice thing is that under each "hump" in the busbar, it is solid plastic, so the nut slides into place easily. I then drill a hole in the hump, being careful not to go too deep. I slide a piece of paper into the hump so catch any debris, and do a lot of vacuuming. I worked on it Friday afternoon, and all day Saturday, and I am pleased to say I'm half done! Yay! I've done one of the 4S batteries and 2 of the 5S. It took longer to do the first battery, as I was refining my method. Today I made all the nuts at one time, then I made all the plates. Then I drilled the humps, and assembled it. Then I cut the cover so that I could snap it back into place.

Tomorrow I'll continue, but I can't be sure I'll finish. And even with the plates in place, I'm still able to use the BMW plugs and get them to plug in and out. I can even use the straight plugs. It's only the 4S batteries that give a problem with space, as the 5S ones dont require a plate so close to where those plug in.