First discovery. Damon didn't run 2 gauge wire from the converter, they used 6 gauge. So, I have a ~40' run using 6 gauge from the converter to the distribution panel to the disconnect. In a perfect world that's a .63v drop ALONE at 20A. At 40A it would be a 1.26v drop. Add in losses at connection points and the additional ~20' of 2 gauge wire and the expected voltage drop is not far off 1v drop I'm seeing.
It's quite possible I'm crazy and the converter was never charging the battery at high amps but I'm fairly sure it was. Finding this long #6 wire run really makes me wonder how that would be possible though.
It looks like I'm fighting a design and implementation issue, not a bad connection issue.
Very annoyed.
