Do you know offhand how people generally route cables from one end of the vehicle to the other? I'm assuming underneath the car, in the exhaust/transmission tunnel. I was thinking we could get some plastic conduit and run it inside that for protection from the elements.
I'm not sure what the common method is, but I was thinking of doing the conduit method as well. Seems to be a safe way to pull it off. Safer than running through the car at least. I look forward to seeing the pics of your lug-less cable ends.
I know... I kept firing up the torches at the back of the car this afternoon, and every time I did I thought, "wait! gas fumes!"
I don't think the cables will melt. Unless I really misunderstand what's going on, the 4/0 is WAAY overkill. The internal wiring inside the motor itself is more like 2/0 size. That's what I'm more concerned about melting...
In further "misunderstanding what's going on" news, today was the first time since the start of the project I mistakenly shorted out pack voltage. Freshly charged, too. !!!ZORCH!!! I vapourized the end of a 2/0 lug. :O