12V Connector Box

thingiverse

This is the case for a 12v connector box, it fits panel mount connectors like Anderson PowerPoles, 12V cigarette lighter sockets, 12v USB adapters, etc. Mix and match panel mounts as you like. If you don't understand electrical safety, fuses, & wire gauge, don't build this project. First, go get your amateur radio license and learn some stuff on basic electrical wiring and safety. Get an Elmer to help you! I wire a Anderson PowerPole pigtail about one foot long through the small rectangle hole on the side. You may install a zip tie on the inside of the box as a strain relief to help keep the wire from pulling on internal connections. This pigtail is a good place for an inline fuse. (see cover variant) From battery pigtail wire, connect the switch and fuse in series to the (+ red) & (- black) banana posts. Next, connect all panel mounts in parallel to the banana posts. (See schematic diagram). Mount the higher current panel mount devices close to the banana posts. This helps keep wire shorter. The lower current 5V USB and voltmeter devices can be at the far end. Be sure to use sufficient gauge stranded COPPER wire for the current load plus margin for safety. Typically 12-14 gauge wire. You should research the current load you need for your needs. (battery, wire, fuse, and load) Do not omit the series fuse. Batteries will produce very high currents when shorted. The fuse is not optional. It is required for safety. It is better to blow a fuse than melt everything and burn-up. You could use a circuit breaker instead of a fuse. 1) ABS, 100% infill for strength. (pla works, but may warp in the sun) 2) #8 x 3/4" Pan Head Phillips Sheet Metal Screws The first photo is a 3 hole prototype. I changed to the larger 4 holes configuration since the connector box will still fit in an ammo box with the battery. I will post photos of the 4 hole part once I finish the wiring. The photos at the end show the original battery box inspired by Tony W6TNY. Later the clear bottom connector box was what I demoed to fellow hams at SOARA meetings. (www.soara.org) The benefits of the connector box are: 1) Expensive panel parts are more portable from battery to battery. 2) Connector box can store inside an ammo box keeping everything clean and protected. 3) Ammo boxes with batteries can now stack. Previous designs with connectors on ammo box lid didn't stack well. 4) Electrical Wiring not exposed to possible damage or snags. Second cover variant removes holes for switch and fuse. Use inline fuse in the pigtail. Unplug at pigtail to turn off. Moved holes for banana posts to give more room for wiring terminal rings. Be aware some taller panel mount devices like the 12 v lighter socket may need 90 deg spade lugs. Otherwise, the box isn't tall enough. 73, Ed, WA6ED