Time to make my own buss bars, please help

[zack_e89]

Ok so I've tried to do my research and this is what (I think) I've figured out so far:

-I believe CJ mentioned using this material http://www.discountsteel.com/items/6061_Aluminum_Flat_Bar.cfm

-I want to make one pair for 4 D3100s which are ~7 inches wide a piece, so they would need to be ~30 in long

-Need a pair for a D3400 under the hood, so ~7" long a piece

What I'm not sure of:

-How thick and wide should I go? Is 1/4" by 4" close?

-Am I getting the right idea here? http://www.discountsteel.com/items/6061_Aluminum_Flat_Bar.cfm?item_id=133&size_no=28&pieceLength=cut&len_ft=2&len_in=0&len_fraction=0&pieceCutType=12|1&itemComments=&qty=1

-Would I be able to do this all with a drill? I think I would just need to buy the bolts and use the correct bit accordingly?

Thanks for any advice.

[rockFord_Expedition]

A drill press would be ideal but a regular drill could get the job done. Make sure you thread the holes for best results. Just be safe and have fun, that's what it's all about.

[TRON]

For tapping the right hole size, lets say 5/16, you should drill a 9/32'' hole to get 50% thread lock (the space between the thread in the bolt and hole).

Basically if you drill a 5/16'' hole, you wont be able to tap it to 5/16''

Id also use stainless hardware with 6061 aluminum.

Edit: Tapping chart: http://www.physics.ncsu.edu/pearl/Tap_Drill_Chart.html

[zack_e89]

Thanks for the help guys!

For tapping the right hole size, lets say 5/16, you should drill a 9/32'' hole to get 50% thread lock (the space between the thread in the bolt and hole).

Basically if you drill a 5/16'' hole, you wont be able to tap it to 5/16''

Id also use stainless hardware with 6061 aluminum.

Edit: Tapping chart: http://www.physics.ncsu.edu/pearl/Tap_Drill_Chart.html

Thanks for the info and the chart, that really helps! Maybe that should be stickied somewhere? haha

Edit: Would this work well? http://www.ebay.com/itm/1-4-x-6-6061-T6511-Aluminum-Flat-Bar-x-36-Long-250-x-6-6061-Flat-/150720962692?pt=LH_DefaultDomain_0&hash=item2317ab6084