OK, so directly flattening / soldering / flattening the cable end

Those cables look used. Where'd you get them? 20ft of 2/0 AWG welding cable is expensive :-(

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.

Rear flattened/soldered/flattened batt interconnects turned out well and are installed. Picked up 2 lengths of plastic 1 inch ID conduit as well. Continuing to plug away this afternoon...

Conduit is probably better than what I was going to suggest :p

Large garden hose :thumbup: It's flexible and you know it's water tight :thumbup:

Ooooh. Garden hose is a good idea if you're using 2/0 gauge. It would be a little more saggy than the conduit, but you could work around that.

Duh, I was worried about the exhaust pipe when you mentioned conduit under the car. LOL :)

Cool Cables, lets hope they don't melt :)

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

That soldered cable end that turns into a lug is fantastic! Really, really good. Could you post up a tutorial so we don't all have to go through the learning curve please? :)

I second this request!