An improved method of manufacture for electrolytic cathode devices that include a copper hanger-bar with a rounded underside that ensures the automatic vertical positioning of the cathode's blank starter sheet with respect to horizontal supporting bus-bars irrespective of warpage or construction defects. The mechanical connection between the hanger bar and the starter sheet is achieved by inserting the latter's upper edge into a receiving groove in the underside of the hanger bar and by welding the entire length of connection, thereby establishing a large boundary surface for good electrical conductance. One embodiment of the invention also features notched lateral edges that increase the rigidity of the starter sheet and allow the ready installation and removal of conforming insulating strips.