Hi Terry,
the current isn't a problem - it's only about 1.5 - 3 amps (I'm amazed that alkaline cells stand a chance of heating a wire to red heat). The pololu connectors are great for sticking into a pcb, but the simpler nylon 'chocblok' type are easier to mount in this case. My reasoning for the copper wire extensions was to provide a good electrical contact (fine wire into a screw terminal can be erratic) - and also to shift the red hot wire out away from the connector a little. I'll stick with the nylon connectors but, of course, anyone can try something different. Coming soon...
