Bus bars looking bad

Hello ! newbie here but long time listener!
I have had my lil 2005 Prius for just a year, always admired the car, and am always trying to get the best mpg that I can, got this car at auction for 1500$ slapped some tires on and a ebay cat and O2 sensor and she was road ready! Got her as a side piece to keep miles down on my 2006 Tundra and figured the car will pay for itself over time by mpg being in San Antonio TX the occasional drive down to Austin, San Marcos, Houston, Luling, Buc-ee's, rivers, ect, is where I wanna be on a off weekend, when I decide F+$# it, mowing the lawn can wait ! I thought this care will be a wonderful addition to commute and ease of mind not having to worry about my truck being broken into or stolen (is old but its still a thing in Texas) Ps I work at a Wal-Mart the king of missing vehicles! anyways car ran good did the first oil change to switch to Supertech synthetic (I know what some will say but hey its a hobby/commute car) its been fine, did some at home window tinting, removed interior and pressure washed it ( usually do this cars gets rid of smells, stains, good way to air out the car sort of speak ) I foam cannon everything first with a cleaner like Mr.Clean or Fabuloso let it sit for 10-15min rinse with pressure washer, then hit it with the foam cannon this time with laundry detergent (Gain) let dry for 1.5 days in the Tx sun and bam less back aches than using a slow wet vac or steamer, anyway Fast Forward, car does great its been to a good stretch of Texas travel, but I kept wondering is it the age or the miles on this car that I only get 41MPG ? I was jelly since I had seen on Prius Chat that some people boast 48MPG, I wanted more! I ran Lucas cleaner in the tank (big bottle) and drove like a granny but still couldn't break the 41MPG! oil burned about a quart between oil changes (current miles 284K dont remember what it was when I got it) I'm very cheap, so air filter is still the one it came with spark plugs where fairly new service records indicated about 1.5 years old so I left them in until about a month ago, trying to get better mpgs! got a can of CRC intake valve and turbo cleaner, did a heat soak and overnight soak to the pistons, and cleaned the throttle body some gunk in the intake manifold (what can be seen at wot) did a intake soak as well, heated and soaked for one hour then hwy drive and oil consumption is way down so far (unless Supertech has drastically improved lol) Warning ! I did not ! change the oil after the CRC soak on the pistons!!! and it in fact is still in the crankcase, at first I got to busy to change it then sick from allergies @_@ but ! I did bump my avg. mpg up to 42 at first and most recently to 43! I figure that PEA is giving my engine the business! but still small win because I still been driving like a granny and using the B shift to get an extra charge up (ps did I mention the ABS lamp came on so my braking stinks rn) I got curios since the miles and the fact that it was only after the batt would get a full charge up that I could actually feel just running on batt only for the short mph range, I began to wonder is this a original hv batt ? could something be needing attention ? then I started taking a closer look at the "Bus Bar" threads! and just yesterday decided to take a look at my bus bars @_@ I'm not sure if there is a thread for "bus bars of shame" but I think mine will deff qualify ! I started opening up the case and saw signs of "someones been in here before" missing bolt, bolt hole misaligns and figured I'm probably in the clear it might just be the Texas heats high AC demand once the casing cover came off and I popped off the bus bar covers, I was thinking boy was I wrong ! Bus bars are black like worst than Ive seen on prius chat but oxidation or crustiness although bad around the bolts is not as seemingly bad on the center of the bars but still showed signs of heat buildup due to resistance, when I saw the battery cable leads I got a bit worried since during disassembly I could feel a difference in the flexibility of the cables I though maybe its just a small piece 1-2 inches of corroded cable, but still I was wrong! the battery lead facing the trunk had close to 4,5'' of corroded cable while the battery cable facing the rear seats had a astonishing 14'' of corrosion, I untwisted them to check how bad it was and it was inside all the major strands the two cables in question are negative leads as well, I said well lets see what we can salvage, bus bar bms leads are less than great : / might try to find a replacement, bars and nuts removed and sprayed with Remove+, had it on hand since I got it when I switched batteries in my tundra and had constant issues with green corrosion on my terminals but once I used this stuff my tundra hasnt had a issue with green crud on the terminals, next went on to check the module or bms module since I thought surely the corrosion has reached it since it is a issue at times on these packs, but to my surprise it was in pristine condition (see pics) so no issue there, but now I have a cable issue, a nut and bus bar issue, PS left the bus bars and nuts soaking then soaking in vinegar after the remove+ spray down and they arent looking so good, this is a budget build sort of speak so sanding them down is likely gonna happen but the batt leads are a must to replace! although I am going to try to clean them up and get a measure on mpg while I find replacements again I'm cheap so I'll wait for a good deal or retrofit, prius app shows module 6 is the lowest performer for voltage followed by 12 will check once repairs are done, blocks 1-9 shows 25 mili-ohms, block ten was 26, block 11 was 24, 13-14 were 25
im cheap so bus bars will likely get cleaned up and I will likely replace cables, still researching anti corrosion coatings on the cheap but will likely just place them back in and inspect in a few months hopefully I can close out this thread in a months time to be able to give everyone feedback, thanks !

 

Day 2.5 bus bars have been soaked in vinegar overnight where still terrible, left in acid bath for a good while then they did better but the nuts and bars are so bad they're pitting so bad I tried knocking it down with 400grit wet /380/ 220 / 120 and still the pitting was so bad (see pics) I could get them shined up nice but just had pitted circles idk how many thousanths I took off already ! I decided to throw in the towel and order up some new bus bars and nuts ! The nuts are also badly pitted hit them with the same grit sequence if I wanted them to shine up if probably be there all year @_@ (couldn't find my dremal brushes)
Battery leads have cleaned up nice just working one area still (in the bucket pic) thats real bad in the center winding, gonna be retwisting the copper and giving it a quick low temp heat up to hold its twist and cool down then start reworking /melting the insulator sleaves back together, gonna hit the leads for the computer with some vinegar and a toothbrush, already hit it with batt terminal cleaner which worked well btw

 

I found some on eBay but way out of the budget range @_@ just gonna rework them, and junkyards around here don't leave the batts in and it's impossible to find a part out car that isn't instantly missing everything ya need ya know lol

Yup will be ordering those today since my defeat this afternoon lol

 

So my Amazon order was delayed and I ended up cancelling the order for the bus bars went ahead and order from. (Acenbay)as recommended I'm in San Antonio and they're in Dallas so I hope I get them in soon liked the wide flange nuts more coverage = less corrosion, the pic from the site was the selling point for me the repeat heat of the bus bars will warp them more on the smaller flange nut so when it's the same as the base or backing it's less to be left to chance, replacement cables will probably be in Friday or sat, I'll do a out two weeks of driving (if components don't fail) and check my mpgs maybe longer then switch out since the Texas heat is coming soon @_@ I'll keep y'all posted

 

Finally got my bars in install went ok, as for the long lead that was crispy I won't be able to use ATM when I twisted it back together I twisted it too much so my cable ended up short so I went ahead and installed the replacement that I had ordered, I'm getting some batt codes also but it's when I hit a bump in the road ️, dr.prius app (see pics) reports the resistance has gone down ! Prior I had one at 26, one at 24, and the rest at 25,
With the new bars I'm at 19 across the board! Voltage is at 232 @ 51% state of charge when prior it was 214 @ 53% soc ! So far happy with the results just gotta get my contactor issue under control again I haven't assembled the hv batt covers so that might be it also, unless I did something wrong updates will follow and the quest for mpg will continue any input is appreciated p0aa4 / p0aa1 / p0a94 / where the main codes that popped up

 

Also mods #6 & # 12 are doing better 6 mingles with the rest like normal but 12 still seems to be lacking but still shows improvement

 

finally got around to getting the covers back on the HV battery and sure enough all my battery codes went away! haven't even driven 100miles yet but I can feel the difference and I'm no longer being a granny with the throttle! actually gave it a fuel injector cleaning (amazon tool) with gumout 16oz and gas 50/50 just as a lil preventative maintenance, having done all that and testing the battery out and watching it on the dr.prius app I'm happy with the results so far haven't gotten my mpg up but still gotta do some drive cycles, on another note, a few months back my besties mom was using my prius to shuttle the grandchildren to school across town since mom was sick, and my besties mom is like 5*1 ? if that and drives a dodge 2500 and was telling me its about 40$ a day in gas @_@ (heart attack) she was stressed so I handed over the prius ( I live 10min from work) and my trusty 2006 tundra is good enough on gas and has enough hauling power, fast forward after a few months my besties mom tells me somethings up with the car, that the rear tires are locking @_@ I go in and take her apart at the drums and yup they are out of wak at 280+ on the odo, they appeared to be stock but I cant confirm that get some new shoes in bingo bango back on the road! then a few days later she tells me the front brakes aren't working and the abs light and vsc light are on, I do the bootleggers bleed on the rear, then the front for good measure, but no luck, groundout codes reveal (dont remember) like code 53 on abs which lead nowhere and vsc code 47? couldn't find any reference material on the matter, so I've been driving like that for a few months now, I know I probably need a new set up but havent been able to make it to a recycle yard, (today) finally decided i was gonna drop some dot 4 in the system to see if I could prolong the inevitable, so I start bleeding out filling with random dot 3 I found around the house had 3 small bottles, 1 quart bottle, and a half gallon (didnt use the half gal & one of the small bottles) only bleed the rears and RR was yellowed but still to the naked eye seemed passable, I said Ima keep on going, extra long bleeding, then did the RL, and called it a day, actually re installed the rear upper seats and everything in the cargo area, the wiper cowl since I was also thinking ima take the weekend to go get another brake mod and order up the vc tech stream stuff to get the brakes right, but still ended up saying lemmie try this real quick on the dot 4 since I already had a bottle (havent used) because that what my harley calls for, I stopped with the dot 3 because the cycling on the pump started to change, I said fuk it lemmie try this out real quick got on the road front brakes are working normally after maybe a block the abs vsc turn off @_@ got a few miles and so far so good I still freak out when I start the car since the dash lights linger lol, the pump cycles way less than before, gonna bleed the front soon and report back later but for now just happy i only have my tpms light on and cel (p0420 and whatever the coolant valve is) lol no more xmas dash for the mean time!

 

Quick update, been driving as usual only up Maybe .5mpg in the mid to high42 mpg and hitting 43 once in a while, took the plunge and upgraded the dr.prius app to get the test on it done to see if maybe I needed to look elsewhere to tweak something bat test came back OK, batt life came back at first 63% (might have been user error) (should watched the tutorial first) second go around I got 69%, I'm debating if I should save up to get a charger and do the discharging to freshen up the battery and hopefully get my mpgs up, if anyones had a similar situation or positive experience lmk thanks !