via EV wrote:
I might well be fighting a losing battle, but for the price of 4 holes in a 
strip of material it has been a great education.

Tonight I tested the different alloys of Al idea.

Last time, 0.02 x 1.75 in strip of roof flashing aluminum:
~120 F temperature rise in ~15 seconds, cross sectional area 0.036 in^2

Tonight: 0.1 in diameter aluminum welding filler rod
~30 F temperature rise in ~90 seconds, cross sectional area 0.016 in^2

I was rather impressed that<  1/2 the area had ~1/4 the temperature rise! My 
guess is the welding rod is a more conductive Al alloy than the roof flashing is 
the big difference.

Great to see some actual test results!

A quick comment: Pure metals are much more conductive than alloys. Most hardware store structural aluminum is going to be some alloy -- not what you want as an electrical conductor! Look up the conductivity of the various aluminum alloys and you'll see what I mean.

Get some PURE aluminum to test. If you have to get it at Home Depot, then buy some aluminum *wire* and spread out the strands to make a flat strip.

There are also aluminum solders. They actually work pretty well. You could place a bunch of strands of aluminum wire next to each other to make a flat "bar", wrap a thin piece of aluminum flashing around them to hold them in position, and then solder them together at the ends. Drill a hole in the ends of the bar, and you have a high conductivity (yet somewhat flexible) inter-cell jumper.
--
If you would not be forgotten
When your body's dead and rotten
Then write of great deeds worth the reading
Or do these great deeds, worth repeating.
        -- Ben Franklin, from Poor Richard's Almanac
--
Lee Hart's EV projects are at http://www.sunrise-ev.com/LeesEVs.htm
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