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newsPowerbox external assembled
This is continuation of the new lithium powerbox project. Previous post:
https://bkhome.org/news/202004/powerbox-side-panels-and-battery-clamp.html
I have cut out the front and back panels, here it is assembled, front view:
...no internal wiring yet! Here is the back view:
So, in retrospect, am I happy with the design of the box? If it was done again, would I change anything? Yes...
- I used 6mm ply front and back, which is too thin. The Anderson plugs require considerable force to plug-in and unplug. I strengthened with some strips of pine screwed on internally, however, use of 9mm ply would have been better.
- Dimensions are a tight squeeze. OK, but if someone wanted to use a slightly different battery, it probably wouldn't fit. For my Amptron 50AH battery, I would have preferred an extra 5mm internal height, to make sliding in and out via the side easier -- though probably once it is in, it will stay in -- I expect the battery to outlive me.
- It might have been simpler and easier to go for a wood frame
rather than aluminium. Bunnings sell 12x12mm section medium-hardwood,
which would have done the job.
I used SolveSpace to figure out where to place the cut-outs on front and back panels. Here is the front panel layout:
...the 165x170mm rectangle is the internal battery, so there is
nothing cutout on the front panel in that area. Here is the back panel
layout:
...again, the battery is shown. The two 48x74mm rectangles are not
cut-outs -- that is where the 30A circuit breakers will mount
externally.
I painted it aluminium-silver, however, reckon that matt-black would
be more appropriate. Black would match the DC-DC charger, and some of
the power sockets.
There are a couple of details to finish off, before starting on the internal wiring.
EDIT 2020-04-21:
For the record, this is where I purchased some of the items screwed onto the front and back panels:
I ordered one of each colour of the Anderson
panel-mounts. The vendor agreed on one payment of AU$9.90 to ship all
three by Aust. Post Express (you have to ask for that):
This is the cigarette lighter socket:
https://www.jaycar.com.au/dash-panel-mount-cigarette-lighter-socket-with-cap-15a/p/PS2004
Binding posts came from Altronics:
https://www.altronics.com.au/p/p9225a-heavy-duty-red-50a-binding-post/
...they have holes for banana plugs, but
Altronics also have binding posts without the banana plug holes. Note,
the tops screw right off, so that eye-type lugs can be attached.
The externally-mounted 30A circuit breakers are
available from many places. They are very expensive from some local
vendors. I purchased via eBay:
EDIT 2020-04-22:
Here is another vendor of the flush-mount Anderson housings, at almost half the price. They stock grey, red, black and blue:
https://andersonconnect.com.au/store/index.php?main_page=product_info&cPath=36_72&products_id=352
Tags: nomad