Is it ok to use aluminum for a busbar, or power distribution block?

moparmarks said

Yes very correct but were also talking about 12 volts, not 15KV. You really think he will have problems with that piece of scrap? Yes there are better materials but I don't think he building a rocket here. I just think he is fine with he has made but everyone says to toss it and start over.
And as a side note if you have ever pulled 500 MCM then you would know that aluminum is much easier to deal with than copper, but not superior.

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True, but once that aluminum oxidizes it turns into a little heater element at the point of connection. The aluminum plate is just fine to carry a lot more than any car would need for just about any circuit, but how things are attached to it is where problems come from.

I like the suggestions to use some sort of fuse box though - didn't occur to me but I built a couple like for those for similar purposes and it works great. I was dumb though and paralleled two fuses one one circuit (I think for the alternator charge line, even) thinking it would be fine. Nothing but trouble..

I hate that he is tossing it because it really is a very good looking peice, especially compared to the cobbled together junk so many guys hack together. Just hate to see it also be a point of pain when/if the connections fail or burn through.

As far as pulling wire, never done it... I'm the geek who sits at a computer rather than doing the real work ;) but I've done enough back breaking labor to appreciate dealing with lighter assemblies! Like I said, in utility work there's enough benefits to offset potential drawbacks and risks, completely different world.