[Model51]

I appreciate your persistence on this effort. Making the case to the level of precision you are doing is not a trivial effort. Thanks for sharing your processes and results. You are doing a great job on this project! Can't wait to see the end product once you are done.

I had the same issue with the height of the Optima battery posts that i think you may be having. I used 3/32" thick plastic on the top to maximize the terminal post height.

Also, at least for a Type 40 battery, the distance between the centerlines of the post was a bit longer so if one were to look closely, the posts don't quite align with the lead connectors and the caps, but it's a trivial thing and one that can't be avoided.