They may not be pretty... but they work...
Starting with 1/2" thick walled copper pipe, and flattening it with a hammer. Each bar is 7" long. Then mark out where yer standoff bends will be to raise the middle section of the bar is raised away from the "wall" surface. Measure our the mounting screw holes. Then the holes for your connection points.
I used 1/4" bolts, at 1" long, you need two nuts for each bolt, one for locking the bolt into the copper bar solid and one to use for your wire connection to tighten down. I used a heavier bolt, 5/16" x 1" long for the main bolt that will have the battery bank connection hooked to it. These have the same double nut on them for making sure connections are solid.
for a base where they are fastened to the control wall they will have a runner block that the ends of the flat bar slide into to completely incase them in rubber to avoid current flow.
I would love to be using the professionally made bus bars but at $25-30 a piece they're not in the budget. So home made it is... and even though they're not perfect they're solid and safe. Well as safe as anything to do with electricity can be to work with. A future upgrade will probably be to replace them with better quality, but for now they'll do.
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DIY Homemade Bus Bars For The Next Solar Upgrade
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