[edit] Off Shelf

Touch Safe Terminal Blocks - Mcmaster Carr 7618K618

Top Access Terminal Blocks - Mcmaster Carr 7527K53

[edit] Introduction

[edit] Design Goals and Paths

The objective is a redeployable, fault-protective series of wire clamp pairs (each pair being electrically conductive).

Insulator Frame: HDPE

Conductive Bridge: Aluminum 6061T6 (abundant aluminum, easy to machine) (note: watch out for galvanic corrosion!)

Fastening Screw: Stainless Steel 304, socket head cap screw

[edit] Materials

Stainless Steel M5x0.8, 16mm Lg Socket Head Cap Screws

HDPE Natural White 0.06" x 12" x 24"

HDPE Natural White 1/2" x 12" x 24"

Aluminum 6061T6 1/8" x 1/2" x 72"

[edit] Steps

For cutting, you'll need a saw (ex. bandsaw) or shear machine of some kind.

For making holes, a drill or punch machine is required.

For tapping, a hand tap or low-speed hand drill with a chuck is needed.

You'll want to cut the thick HDPE to size, ex. 1/2" x 1" x Length Now drill the thick HDPE piece with a 4.5mm diameter drill bit for the screw terminal holes and a 6mm diameter bit for the mounting holes Tap the screw terminal holes with an M5x0.8 tap

Also cut the thin HDPE to size, ex. 0.06" x 1/2" x Length (ex. 1")

Also cut the aluminum flat to drilling size, ex. 1/8" x 1/2" x mountable length (ex. 9") for mounting onto a vise while leaving space to mount onto a bandsaw for cutting out the small pieces Also drill the aluminum pieces with the 6mm diameter bit Cut the aluminum lengths to use size ex. 1/8" x 1/2" x Length (ex. 1") for each conductive pair