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..http://www.flamingriver.com/download2.php/products/c0015/s0007?instructions sorry, i can’t provide the size. I just used a step drill. It does show instructions either. I’d just measure with calipers, but the truck is offsite for winter storage.

Nothing i've noticed. It does give you piece of mind any phantom current draws are gone.

True. Easily defeated, but could be accompanied by a cover lock. Not with security in mind.

Yes 2/0

Yes, key is removable in either position. It is also fairly robust, turns with some force. You'd have to turn it vs kick by accident. I just remove it once turned on. Another thread.... but I thought all military vehicles were designed to run without batteries (jump and run). Not a known...

The connectors are just plain copper. Sized exactly for a 2.0 cable. You strip the insulation, flux copper connector, then use flux free electical solder. Heat will not impact the insulation. A marine store will have them. I am also sure the parts are defined in the technical parts manuals...

Here's what I ended up using. I made the two battery cables, and removed one (part #5578874) from the original setup. Used 2.0 gauge wire (about 6 feet), purchased from a marine store. Soldered ends (4x) (marine store). 2 grommets (purchased at hardware store) fit the 2.0 gauge wire...