2004 HiLo with ELX45 converter.
On my last trip the main 30A breaker failed at the bus bar and damaged both the bar and the breaker (TBBD3020). The connecting bar is too burned to be useful at that position. Has anyone had this problem, and if so, did you find a replacement bus bar? I can find breakers on Ebay or use modified Siemens type QT breakers, but the bar must be replaced. So far the only option I can think of is to make a new one out of 14 gauge copper.

photo of bar attached

Attached Images

breaker-bar.jpg (26.6 KB, 15 views)

Showed your post to DH. You might be able to make the piece out of copper. Possibly get a new 30amp breaker. Consult with Randy at Best Converter out of California. I would have you call DH. Tomorrow he is having dental work. Old bridge removed and two teeth extracted. I'm sure he won,t be in any shape to talk to anyone. Hope you get your problem solved.

Copper bar was made out of 0.08" copper. Two were made - one was identical to the aluminum one, but it was harder to make and not as "pretty'. The best one was made by silver soldering tabs into notches in the copper plate (picture).

Attached Images

fixed-bar-1.jpg (26.9 KB, 5 views)

NOW I see what you had, and what the problem was! For some reason, I could not see the design of the original bus bar in your first picture. I had not noticed this component in my Elixir converter, so I really didn't know what you were talking about. Your new bus bar looks like it will work perfectly!

- Jack

__________________
Hi-Lo 1707T - Tire Minder TPMS on Tow Vehicle and Trailer, 300W Solar Battery Charger, Equal-i-zer WDH, Progressive Dynamics Converter, Fan-Tastic Fan, LiFePO4 battery 12V DC Electrical System
2014 F150 Platinum 4x4 3.5L EcoBoost SCrew