The height of my main on/off switch and bus bar are different - approximately 1/8 inch. I would like to make a custom link bus bar to connect the switch and bus bar as well as a smart shunt and negative bus bar. I am thinking about using 101 copper bar 1/4 inch thick by 1 inch wide. Is 1 inch bar appropriate to carry a max of 400-500 amps? I don’t know if I can find 1.25 width bar. Should I strongly consider 1.5 inch wide bar? Next question; can I cut a 6 inch piece of bar and bend it to accommodate the difference in height between the two components without increasing the resistance? I’m thinking a slight “S” curve in the copper bar.
