[aboulfad]

I already had welding cable and i believe its AWG 00( or 2/0).Benefit of using welding cable is that you won't get any voltage drop between power supply and the car when car is consuming 100 amps.I know its little overkill but i preferred it.

You will have to watch for Dell JD200's on the ebay.Sometimes they are listed dirt cheap.

I used AWG6 for 4 ft, and the voltage drop was negligible. But I think the DSP-600PB doesn't regulate voltage so well at 13.5-13.7 (as we steal the sense pins to raise the output voltage), but it seems yours is "built tough". I am gonna look into it.

In my car series (F8x), the consumption is way lower than yours, I did a similar test as yours but I didn't think of the heated seats ignition on, low beams, interior lights, rear fog light, radio, full fan consumed around 23A. But in any case all accessories are OFF during flashing! Very nice work.