As far as polishing the terminal tops and busbar links, we used a scotchbrite abrasive pads that attached to a drill adapter thingy https://www.ebay.com.au/itm/20229265082 ... R7zmr5q-Yg and the adaptor to fit the drill
https://www.ebay.com.au/itm/31421769893 ... BMquy_mr5i
As far as fuses https://www.ebay.com.au/itm/32353763229 ... R5C69Zq-Yg a single link plate cut in half and then a piece cut out of the flat end to hold the fuseholder so the spade terminal could be soldered on .... and the wire soldered to the other spade terminal .... no bad joints that way, the slightest bit of resistance will throw the voltage readings out showing a cell voltage error where there isn't one.
As far as the link plate, thick rigid links can't flex like the thin ones with the hump in the middle. The result is the link will put pressure on the terminal blocks and either cause leaks allowing the electrolyte to escape, or fret under the clamping bolt causing it to loosen under the bolt .... a loose terminal at 48v = melted terminal block and stuffed cell ... there are hundreds of examples on the interweb of the terminal overheating, melting the plastic and destroying the cell ... your call if you feel the cost saving on the links is worth the risk of destroying a cell or 3 .....
I didn't do 12 yrs of research and not learn what works and what doesn't ..... making terminal links rather than buying ready made would have been a lot cheaper for us if it worked,
T1 Terry
