The following is strictly my own opinion regarding star washers. 
Others here probably have lots more experience than I. 
The following is also regarding bare metal-to-metal 
contact only.  I always require masking off around the 
area where grounding is done. 

First, the only way the grounding integrity of whatever 
you end up doing can be checked as being sufficient 
is to check it with the ground current test. 

Second, the integrity of the ground is highly dpendent 
upon the torque imposed upon the the nut or screw 
used for securement.  Get a calibrated torque tool 
for the job. 

Thirdly, I've had some very serious discussions with 
some NRTL test engineers regarding external toothed 
star washers versus internal toothed start washers. 
It was *require* at one time for me to use internal 
toothed star washers to protect the integrity of the 
cutting action of the teeth to chassis. It was *suggested* 
at another time by another engineer to use external 
toothed star washers so that the integrity of the teeth 
could be easily inspected. 

My personal preferences are: 
1) use only metal-to-metal contact for any sort of ground, 
2) if in any doubt - test it. 

Regards, Doug McKean 



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