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The capacitor board measures 12" x 3.5". The capacitor lead and bolt hole pattern was printed on a
laser printer (legal size paper), then glued to the board, in similar fashion to the drill template. The holes are all drilled the same size, approximately 0.062" in diameter.
Next, the capacitor copper pattern was glued to 12" x 3.5" piece of 20 Gauge (0.032" thick)
electrical grade copper. A scroll saw with a metal cutting blade is used to cut out the copper to
the correct shape.
The copper is then epoxied to the FR4 using high-temperature epoxy (Manley 40180). The epoxy must be able to withstand soldering temperatures. After the epoxy cures, the holes are drilled out to the correct size: 1mm ⌀ for poly caps, 2mm ⌀ for the electrolytics, and 0.149" ⌀ for the #6 screw holes.
Eighteen copper spacers (0.5" ⌀, 0.375" long, 0.149" center hole) are placed between capacitor board and the bus bars to prevent the capacitor board from shorting the M- bar. The spacers were machined on a lathe, but there is no reason two 0.5" x 0.5" x 12" copper bars couldn't be drilled with 9 holes each.
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