FIRE HAZARD — UNDERSIZED DC CABLE WITH UNDOCUMENTED SPLICE INSIDE PASSENGER COMPARTMENT The 2026 Midwest Automotive Designs Luxe Cruiser D6 (VIN [XXX] , Unit #[XXX]) contains an undersized negative DC cable carrying 304 amperes continuous through a conductor rated for 195 amperes (2/0 AWG copper), representing 156% of rated capacity under NEC ampacity tables. Motor-starting surge loads can exceed 400 amperes (205% of rated capacity). This cable is the primary DC negative path between a 1,080Ah lithium-iron-phosphate battery bank and a Xantrex Freedom XC PRO 3000 inverter-charger. The hazard compounds at the floor penetration inside the coach passenger compartment: the cable transitions from properly-sized 4/0 AWG to undersized 2/0 AWG at a bolted lug splice wrapped in white electrical tape. This splice is located inside the vehicle where my family rides. It is not documented in any build record, inspection report, or repair order. Photographic evidence ([XXX]) reveals that both copper lug faces at this splice bear red X markings. These markings are not consistent with any recognized torque witness marking practice (which requires a stripe crossing from bolt head to mating surface). The marks represent either (a) failed-inspection flags placed by someone who identified the connections as defective and left them uncorrected, or (b) non-functional markings. Either interpretation establishes that someone examined these lugs, marked them, and walked away. The Xantrex Freedom XC PRO Owner’s Guide (Rev G, Table 5) specifies minimum 4/0 AWG for cable runs of the installed length and classifies improper wiring under its highest safety designation (DANGER) as capable of causing “death or serious injury.” The Guide further includes a FIRE WARNING for DC connections that are not torqued to 71–89 in-lb. No torque documentation exists at any service touchpoint. ADDITIONAL SAFETY DEFECT: The interior 120V outlets are not protected by GFCI breakers as required INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Source: NHTSA complaint ODI #11739579 · view all complaints for this vehicle at nhtsa.gov