That's an interesting point about resistance in the studs on terminal that I had not considered. It seems like a pretty unlikely problem but I will run it by my "electrical engineering department". Does the locktite provide a complete and reliable electrical insulator between the threads of the SS stud and the aluminum? If not could that create a potentially higher resistance and higher temperatures in your failure scenario? How much is the contact area between the bus bar and the battery contact flat reduced by the plastic sleeve you used? I see buss bars from Blue Seas that have SS fasteners into the copper buss bar.
https://www.bluesea.com/products/2127/MaxiBus_250A_BusBar_-_Four_5_16in-18_Studs
Is the concern the different conductivity of the SS? Brass studs could be used rather than SS. Certainly the strength is OK considering the torque specs?
McMaster has these M6x20 set screws in brass
https://www.mcmaster.com/93038A149/
And these brass nuts:
https://www.mcmaster.com/90690A047/
Dan Pfeiffer
That's a good looking build! It probably won't be an issue but passing current through the SS studs and nuts (should the low resistance path directly between terminal and lug fail) will allow the battery to continue working (at a lower voltage and with a higher current draw) resulting in a very, very hot fitting. Generally, it's better to have a battery stop working than to have it work and become a possible source of a fire. IMHO fasteners should be insulated to prevent ever becoming a current-carrying component.
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