DIY Dual Battery Box - My ultimate box built !

[SinWolf]

Hi,

So for some time I wanted to build a mobile dual battery system which can be removed from the vehicle... I got quotes for Alu boxes and even considered building my own Alu box...

I then discovered that Bushpower sells the National Luna box as a "Box only"... No electronics...

I wanted to make use of a CTek D250S (DC-DC) charger instead of the old solenoid method...

So I picked up the empty box and so the design started...







I had it laser cut and powder coated...







Then the fitting (and test fitting) of plugs started....











Each and every connection was crimped, the soldered, then closed with heat shrink:












And then the final product:

Red Brad Harrison is for Solar panel input,
Grey Brad Harrison is for input from main battery/altenator
Each output plug is individually fused

It has a dual battery monitor, 2 x usb ports, 2 x Hella plugs, 1 x normal lighter socket... The 2 x switches is to switch on (and off) the battery monitor, so that it could be switched of when the unit is in storage, and the same goes for the USB ports which has a blue LED which would eventually drain the battery...

Also fitted fit a 100Ah Lead Crystal battery...

[Henris]

Very nice. Congrats

[iandvl]

That looks very, very good. Well done.

I've got the NL box. My biggest gripe with mine is that the connectors are on the side - and my packing set-up has that side pointing at the wall of the boot. Which means it's a permanent battle to connect / disconnect anything... Should perhaps revisit my set up....

[Martinj]

This is very well made and super neat!

I believe this is a significant improvement on the standard boxes!

[SinWolf]

I've got the NL box. My biggest gripe with mine is that the connectors are on the side - and my packing set-up has that side pointing at the wall of the boot. Which means it's a permanent battle to connect / disconnect anything... Should perhaps revisit my set up....

This will NOT work for me either... Hence my specific design

[blind]

Very nice where did you get it lasercut?

[SinWolf]

Very nice where did you get it lasercut?

I use Kare Sheet Metal in Pta.

[Et1Zook]

Welgedaan! You can start selling these..... Nice!

[ismail]

Well done very smart, add some silk screening or labelled lexan then you have sell-able product.

very smart!!!

[Damdan]

Very smart, what battery are we looking at?

[SinWolf]

Well done very smart, add some silk screening or labelled lexan then you have sell-able product.

very smart!!!

I thought about the label idea... But not worth the effort for a once of

[SinWolf]

also fitted fit a 100ah lead crystal battery...

very smart, what battery are we looking at?

;d ;d

[Quiksilver]

Very nice what was the total cost for the box without battery?

[Kish2604]

Great work... i did a similar set up but with a plastic box...

the laser cut plate really finished of the project nicely!

[Fluffy]

I thought about the label idea... But not worth the effort for a once of

You have done such a fantastic job, don't stop now. Put your name on it and be proud - I would.

[SinWolf]

Very nice what was the total cost for the box without battery?

I will have to go an look... not sure...

Battery box - R450
Laser cut, bend, powder coat - R300
Ctek D250S - R5500
Brad Harison - R70 x 2 = R140
Hella - R99 x 2 - R200
Fuse holders - R35 x 4 - R140
12V Socket - R100
USB ports - R170
Switches x 2 = R50
NL Dual battery monitor - R460
Lugs, cabling, bolts and nuts, heat shrink, solder - R
Labour - R

[Tijmen van der Steenhoven]

Really well done. Very net and well thought out.

May I ask where you bought those fuse holders? I am busy with my own dual battery and no fuse holder boxy thing seem to work for me since I would like all the wires and workings hidden like yours.

[SinWolf]

Really well done. Very net and well thought out.

May I ask where you bought those fuse holders? I am busy with my own dual battery and no fuse holder boxy thing seem to work for me since I would like all the wires and workings hidden like yours.

Communica in Samrand or Mantech in JHB also have them...

Most of the other stuff I got from www.bushpower.co.za

[Therackermann]

Nice job. Well done!!

Always great to see people take pride in their work and pay attention to detail.

[Stranger]

Great job that, it is really cool.