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This 12V DC breaker panel is meant to carry up to 100A, but provides a fairly small stud for terminal connection. The product documentation doesn't appear to indicate the stud size; it was measured with a caliper at 3/16" (#10). The product manual itself recommends use of 2 AWG wire, for which ring terminals/lugs smaller than 1/4" do not appear to be manufactured.

Is it generally safe to use a 1/4" ring terminal on a 3/16" stud? Are there any special considerations? If I were to add a flat washer to stabilize the connection, how would I know what material it should be made from?

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  • \$\begingroup\$ A material that conducts i.e. metal, so brass, steel, copper (but this work hardens) but not plastic... \$\endgroup\$
    – Solar Mike
    Commented Jul 31, 2018 at 8:02

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Automotive starter motors aud alternators use copper washers on their high current stud terminals, So it'd go with that.

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  • \$\begingroup\$ Would I need to worry about galvanic corrosion if the other hardware is made of a different metal? \$\endgroup\$
    – intuited
    Commented Aug 1, 2018 at 6:13

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