wsbca wrote:
There are square crimps. That was one part I could not properly replicate when I did mine with the Leviton replacement cable (and I think it may be somewhat important, in the early days of the EV Project, techs went out to "recrimp" all units and I think this might have been the spot). Since I didn't have the tools or knowledge to reproduce the crimps I salvaged the old ones off of the old cable and wire-nutted little tails of the original wire to the new cable, which I'm not sure is really that great of an idea and maybe worse than screwing the terminals down on the bare stranded wire, but it's all I could come up with and it seems to be working.
Oh yeah, I think I remember it now and I also suggested using Polaris connectors instead. I'm thinking there may be enough room to add a terminal block with set screws right below the contactor onto the chassis. Or maybe just something like this?

'11 SL,
totaled
-1CB@33k/21mo, -2CB@53k/33mo, -3CB@68k/41mo, -4CB(41.5AHr)@79k/49mo, -5CB(38.85AHr)@87.5k/54mo
-0CB(66.14AHr)@87.5k/54mo (
BBB), -1CB(53.92Ahr)@140k/29mo,
51.1AHr, SOH 80%, 150k miles
9kW Solar