I made some busbars tonight based on your measurements (thank you). Here they are:
View attachment 7822067
My steps:
- I used tin plated copper lugs, metric size 10-8 (meaning 10mm2 wire size and 8mm hole size). The lug fits onto the CTEK 250SE terminal, as I checked;
- I used 8B&S wire cut to 7cm in length (with the lugs I used);
- I crimped the lugs onto the wire, remembering to have the clear shrink tube on the wire for both ends, before crimping the second lug on. After I crimped the second lug I heat treated the dual wall tubing to each end.
- I made it slightly bigger than 98mm (100mm), as the wires can flex and being too short is a problem but being a little longer is not.
- The length measures correctly, but I cannot be 100% sure until I mate the two units together on the bracket, and I need my car for that.
- I might yet wrap the red wire using black or a neutral coloured electrical/automotive tape.
I made a test busbar first, to work out what I would do wrong and then fix it for the next two.
All components are of high quality and I used a large crimper, with an adjustable dye (jaws), to crimp the lugs (
following my own advice under the heading Crimping Tips here).