DIY Solar Generator - Portable Lithium Battery Box Build - Part 1

[@mperdue12]

I did the exact same thing but went with the biggest box of the ridged system that has the wheels and handle. The extra space gave me the room for an extra battery an inverter and a few different electrical plugs and connectors. Going on 4 years absolutely zero regrets. It powers my conversion van 90% of the time but when camping or hunkering down for a hurricane the portability is priceless. At the time I built this box I didn't know there was an off the shelf solution but by doing it myself I saved a ton of money and have the box configured to what I need.

[@kaidesign01]

how much did the two battery system and gear run you if you mind me asking.. ? We are trying to set one up now

[@LocdnessMomster]

What precautions would you need to take with the battery pack during hurricane season? Like if you’re in an area and it floods is that an electrocution danger?

[@Rockybrcyyz]

What's the total output in watts? Any idea?

[@ricksters11]

That was the best example of how to put something like together I have seen yet! Most videos just TALK about how to do it with pointing to the components, this was a legit build video! Thank you! Would like to see 110v outlet added to a set up like this, I have need for one, and various ways to set up charging it back up. Thanks!

[@russharmon6635]

The battery box I have built, I added a led strip light to the outside. It is very convenient to turn on and is able to provide enough lights for a lights out situation.

[@ExploreTrekAdventure]

Great idea.

[@AmiApache]

Nice setup. I did have one build for testing purposes without the inverter. I did build one based in a 5Ah 18V Ryobi One Li-Ion battery with a 200W solar panel. The test did draw the power directly from Victron Bluesolar 75/15 the 12v-terminals equipped with Bluetooth-dongle for monitoring and settings. Works well for small scale devices like the 12V-cooler. The charging was done with 3A with specific settings to the Victron MPPT charger. It did work well, but charge current wasn't enough to run 12V cooler with all my drinks on it and charging it on the fly (The cooler draw about 65-75W of power. Normally i did use it directly from MPPT solar controller without battery and stopped when clouds comes out of hiding :) Like i said, it was a test for the adding a battery. Battery not too heavy as i do haul whole thing with my Recumbent 3-wheeler bike and a trailer attached to it. So, there's a limit for weight in all this. The Ryobi 18V battery doesn't like more than 3A of charging current, so i did leave the idea of that there and run if directly from the MPPT after the cooler drained the battery. Need a bigger battery with a better charging capability or run those batteries in paraller with 6 A charging current. In Finland, similar Li-ion 12V battery as your installation costs an arm and leg. About 1000 euros each. I'm planning to build solar battery from 3.2V cells instead. It's cheaper, alot. Nice to watch these kinds of setups.

[@artbarrett469]

Awesome brother. In 6 months I'm setting off on my 4 Runner trek down Route 66 from Chicago to California. 3-4 week slow adventure. I'm gonna build this setup! Thank you brother!

[@Sandnessen]

Really well thought out setup! I'll soon be making something similar, but with an AGM battery. As for possible suggestions, you could consider an internal led light mounted in the lid, that powers on either manually by a switch, or automatically as the lid is opened (kinda similar to how some closets etc. are set up). The idea is to get a better overview if you need to check inside the box for some reasons, while it is dark where you are at. It's all about that convenience! :) Thanks for the video!

[@brettmoritz3698]

Love that you used the Rigid Box. That system is so versatile and rugged, so it totally makes sense!

[@ExploreTrekAdventure]

Yes it’s a great little toolbox. 😀

[@johannwolf1]

@@ExploreTrekAdventure yes... they are great for the price. I worked in film and photo and used pelicans for decades... now I have a pretty extensive assortment of these and love them... makes sense to do this now too. I like the idea of stacking extra batteries too. I would incorporate a robust inverter to power tools for homesteading off grid.

[@beetooex]

EDIT- I was mistaken. These are actually PWM controllers. Aren't the Blue Solar charge controllers only PWM? I think it's a false economy not going for a mppt charger. The output of your solar panels will be a lot lower.

[@thejonc799]

I built a Li-Ion box out of a pelican case and 152 18650 batteries. It is 1.8kWh and I use it almost specifically to charge my Jackery explorer 300. When our fridge is plugged into the 300 and the battery is charging it, it will go for about 3 days consistently. I like these kinds of projects and am planning one with some Eve 280AH cells

[@stevemikel4966]

Nice project, one thing I have discovered using the USB marine type chargers, is that the touch switch can be kinda finicky in cold weather. I opted for aversion with a regular switch to put in my truck, they have a positive shut off- my charger has a built in voltmeter as well and I didn’t want a ghost load. Locking good!

[@zackjablonski]

Really like how you set yours up. I did a similar DIY solar generator and I used a big old Rubbermaid storage bin to fit just about all of the same components plus a 1200 watt inverter, MPPT, and some 12 volt case fans. So there’s a lot of dead space in mine

[@UmpTSquat]

Some people aren't happy unless they find something to complain about. I guess they want to be spoon fed the information instead of putting out a little effort to do some research themselves. HELL! You've already specified the parts and built the damn thing. I find both the video and the build to be very well done.

[@rickbaier1042]

What total cost did you have in your amazing build ?

[@Chevroletcelebrity]

$100 😃

[@nivid01]

$100 = bullshit! I would say closer to $400. The battery alone is at least $200.

[@Chevroletcelebrity]

@@nivid01 it could be done for $100. Your just uneducated and unresourceful 🤨

[@codygeorge1008]

@@nivid01if you look in the description you can look at the links. The battery costs $500 alone! Crazy.

[@michiganmonsters01]

​@codygeorge1008 if you're going fully off grid, it will pay for itself within a year or two. No more energy bill

[@peterbeyer5755]

I’ve seen similar installation where plastic chopping board has been used as support for mounts and plugs.

[@ExploreTrekAdventure]

That is a great idea.

[@craiglush5239]

Fantastic build, only thing I would have done is paint the piece of wood black! Thanks for sharing you’re video with us.

[@shawnfinger5287]

Personally, I think I would have found a board that fits nicely behind the battery, that would act as a spacer so you wouldn't have to cut out the webbing in the lod, and the you could mount your fuse block to it, without possibly needing to drill holes to mount the board. Then if you could find other pieces of wood or fairly stiff closed cell foam to keep battery in place (I know you mentioned putting a hold down strap for the battery. I had to rewind how you used the wire stripper...I think it is opposite of how I would use it, BUT maybe the way you did it, is the best, you aren't dragging your parts that cut into the insulation across your copper (that could nick your copper, and dull the parts intended to cut through the insulation. Nice build! I hate to drill holes in a waterproof box, but to do what you are, unavoidable, maybe make all holes as high as possible incase box gets partially submerged in water. I have some of the rigid boxes and I think they are my box of choice (quality/price).

[@jasonbroom7147]

Very cool build! I did something almost the same, but I used the bottom box (with the extendable handle and wheels) to hold the battery, shunt and solar charge controller. I then used a 175 amp Anderson connection to go from the battery up to the middle box where I have a set of bus bars, various 12v outputs, and a 1,000w Renogy inverter. I then have two 3-prong 110 output from Noco coming out the side of the box to plug in stuff. Yours is definitely lighter and a little more portable/stackable. I hope you have enjoyed using it as much as we have. :)

[@ExploreTrekAdventure]

Sounds like you have a great setup!

[@jasonbroom7147]

@@ExploreTrekAdventure - It works, just like yours does. I can't easily pick mine up and throw it in my truck, though. It's a little too bulky for that, really. It's all about use case and form factor, right? :)

[@chlero_eyes]

Wish the video was longer, this is inspiring

[@ExploreTrekAdventure]

Make sure to check out Part 2. DIY Solar Generator - Part 2 - AC & Solar Charging kzbin.info/www/bejne/nZvZfmaLjd90pas

[@Anthony-kd5ku]

Pretty sweet! I would rotate the usb plugs vertically for easier access.

[@cipropertycare]

Nice build. Neatly carried out. An essential add I would make is a vent at the top side. when you’re charging a lead-acid battery, it gives off hydrogen. AGM batteries absorb most of the hydrogen and oxygen again and turn it back into water, so they’re reasonably well-sealed, yet they still have vents that will vent some gas. But defiantly inspired to make my own. Thank you.

[@jasonbroom7147]

Not sure if you decided to build something like this, but that is a lithium iron-phosphate battery...no potential for off-gassing. I made a similar type of power station and added both intake and exhaust vents (with a thermal switch) to help keep everything reasonably cool on hot summer days.

[@cipropertycare]

@@jasonbroom7147 thanks for that. Really helpful.

[@shawndawson1705]

I did something similar with a regular battery box. I use it for over night fishing and just general power needs. One thing I suggest adding is a small eagle eye light connected to a switch.

[@ExploreTrekAdventure]

Great suggestion!

[@tnacht]

Great for the box part. I think having the directions for connecting the battery cables in order would be helpf

[@allkindsofoutdooractivities]

I’m always a sucker for a good battery box. I love to make them and I love your layout

[@ExploreTrekAdventure]

Thank you

[@missionuluna5837]

U can also charge the battery on a ac power?

[@ExploreTrekAdventure]

Yes. Part 2 goes over the solar and AC charging.

[@razedbywolves8505]

Love it! In a similar fashion I used a Milwaukee toolbox for my ham radio and switches/plug ins for my atv front rack. Thanks for sharing!

[@Robertrls01]

i'm going to be building the same kind of lipo4 storage box along with 2 200ah mini lithium batteries.. looks great.

[@maz8421]

I like this build! My personal application is for in a boat, though (12 ft) so ill be going for minimal size and I'll have 3/8" posts on the outside to hook my trolling motor up. I like the Rigid stacking boxes though because the Radio can clip on to the lid!

[@IMJUSTBILLUNO]

I’d definitely add some type of power meter to tell you how much power is being used and how much remains in the battery. Nice box. I’d would build one like it.

[@RT-qz5ci]

Is there a product you suggest for this? Seems like a good idea but I don’t know where to start with that

[@JohnDoe-df2zz]

The battery has built in bluetooth monitoring according to the website.

[@shelley131]

Just ran across your video. It is perfect for what I want to do. I'm thinking of only using 12V cigarette lighter plugs to run a 12V fridge, a couple of cpaps, and 12V fans. No inverter only DC power. Thank you for sharing.

[@stormtrooper4r]

I use Goal Zero 1500X for all my camping power needs that is recharged using 2 Goal Zero 100w solar panels. It works great and reliable.

[@MarcFain]

Seeing ports have rubber covers, perhaps use a gasket or silicone seal around the hole before mounting ports. Also may be interesting to build an inverter into another Rigid box. Then stack them for AC output in a grid down situation.

[@AdventureswithZack]

I like that idea

[@jasonbroom7147]

That is exactly who I built mine. Also used stainless hardware for anything on the outside.

[@winstonsmiths2449]

Suggestion: try and get the 12v sockets and rocker switches that mount on panels that are made of metal. The metal threads are only on the tube that is beneath the surface. The all-plastic ones can strip easily and you sockets/rockers will rotate.

[@ExploreTrekAdventure]

Great suggestion

[@bslaws]

6:42 I think you'll find that the wire strippers work better if you turn the strippers around so you are gripping the wire side and pulling the stripped cover off with the cutting side.

[@papadale7533]

Great video. Best ive seen. Could you possibly add a wiring diagram to help with proper hook ups. Thank you!

[@djksfhakhaks]

For your iPhone, since apple doesn't do QC charging, you can get a USBC to lightning cable and that will tell the port to output 9 volts for faster charging. Great build!

[@NatureZone101]

Nice! I was trying to find the charge controller and then thought the panel must have it. Looked it up and yes.

[@majorbrighton]

Nice with the toolbox. My suggestion, maybe a 200A fuse instead? So you can use a drill for example. Not shore how your converting the power though.

[@anthonyglaser929]

This would have been a great video if you had mentioned the cost of each part and the specs for the battery and other parts.

[@ExploreTrekAdventure]

You can find the list of parts we used in the description along with a link to the video that goes over our battery & solar panel choice.

[@jimmiesmith7706]

How much was the total cost

[@lancelove9700]

@@ExploreTrekAdventure is paying you to build it for me an option?

[@neonesf5967]

I’m assuming this was just a DIYers project because there is no way this was less expensive / or time consuming than purchasing an 800w/h unit.

[@88njtrigg88]

Nice 1200w unit.

[@jaredcolahan759]

nicely done, My jackery is plugged in full time and the ciggarette plug is always falling loose. I would want studs for the 12 volt.

[@largemarge1603]

Wrap a rubber bungee around the box. . An aside: That would be the only legit use of a bungee.

[@jaredcolahan759]

I have the same issue, There are good male plug in's , but I can't find them.

[@sungod1968]

Great build 👍Could possibly add an extractor fan and vent to remove any excess heat but with no inverter may not be necessary.

[@toddcjohnson1]

I'm going to do a modified version of this for our new camper. Should work great.

[@gaatjenietaanprivacy5023]

Nice video. The only thing I hve to add is do not bind any cable togheter to make it shorter/look nicer. If you bind it in a circle, it will drain energy during use.

[@largemarge1603]

An electric cable in a loop forms a magnetic field. Could that bother delicate electronics?

[@angelv1393]

nice project, looks like a company manufactured device. thank you for sharing

[@Electronzap]

Very nice. I also plan to mostly use the inverter that comes with a pre-built generator. Can use DC from the big battery to recharge the generator that has an inverter if need be.

[@1951Roy]

Thanks for sharing, what was the total cost less the solar panels? Thanks for sharing

[@ramfanweber632]

Nice video on project! I expect people should be able to search for build items themselves! Thanks

[@ExploreTrekAdventure]

We have all the items we used listed in the description box of the video. 😀

[@bobmcmenomey4924]

Nice build. The only suggestion would be to add a blade fuse to the Victron battery charger lead.

[@ExploreTrekAdventure]

Good idea. 😀

[@michael_grey]

using this setup, how long will it last on a charge and with your solar panels, how long to recharge battery?

[@steveenter553]

Not only useful, but think you had lots of fun making it.

[@ExploreTrekAdventure]

Yes, it was fun and we learned a lot too.

[@douggoff5784]

We have used the kzbin.infoUgkxOTeIs0vv4_9B5hsmnLsk9r930uDQLu_Y for probably 30 hours with our camper and it’s been great! The noise level is really only noticeable when running the AC and other appliances like the microwave, hair dryer, or coffee pot. It’s not huge like other ones and it has wheels so even at 90lbs, I can move it!

[@largemarge1603]

01:38 Could the fuse-block mount on the inside of the lid? I think that improves access and visibility... ... especially if you mount a light next to it.

[@tompeterson4628]

Question. Shouldn't the battery cut-off switch be hooked up to the positive battery post.

[@ojc147]

Great set up and design. Thanks for sharing this. I definitely want to do a solar generator build similar to this some day :) Thanks for the inspiration.

[@phillipjacobson4457]

I am able to fit 2-80 ah lifepo4 batteries in the short second box from ridgid 2.0 there is space in the middle( 5") same size box used in this video. I am building a 24 vdc power supply for my inflatable kayak motor. A simple on off switch, and a 10 amp inline fuse. And marine twist on plug with cap. Drill the least number of holes i can. The batteries almost touch the lid in the short box. If you need more room to mount inverter and such, i recomend the taller xl box. ( see home depot) i am installing a 24vdc step down to 12vdc box for a future fish finder power as well Pad eyes, and battery cam straps hold batteries in place.

[@joelahnstein2281]

Anderson power pole hardware added to your box would increase versatility.

[@raymondleroe1837]

Would it be hard to add something to show the battery levels?

[@dougmac9267]

You will still need something for the solar to go into before the battery, right?

[@ExploreTrekAdventure]

You do need a charge controller. We went with a solar suitcase that had the charge controller built-in.

[@richardvalitalo3670]

Funny how we used to camp with just a tent, sleeping bag, icecooler and matches. Now we need power everywhere.

[@ExploreTrekAdventure]

We may not need it but progress does offer some nice options.

[@peteniemela9900]

I remember those days.

[@viejosontheappalachaintrai7270]

Is there any way to add a 110v outlet for a low power requirement? I just found a need to power a podcast station at a remote location. Thanks and I liked the DC setup!

[@jcoats5529]

What about having it hooked up to a dc to dc charger?

[@risunokairu]

Get a dedicated deburring tool so you smooth over those saw cut holes faster

[@largemarge1603]

A half-round bastard file.

[@mr.4zero200]

BRILLIANT!!! What’s the total cost for this build??

[@corkydavis5688]

Can you use a marine battery as well?

[@rolandmogle9671]

How would I get a wiring diagram to add a 400 watt inverter ? I literally have the same components that you do with the exception of the jackery, I want to wire in a small 400 watt inverter with all copper wiring.

[@Morningdovecamp]

Nice work! Thanks for sharing. Enjoy the road!

[@jakes1292]

How did that strap for the battery work out? That seems like a major structural addition to the box for people who want to have this thing in the back of their vehicle. Looks great for a garage addition.

[@aelectrician112]

Have you had any issue with moisture or condensation on the inside?

[@darkskys163]

You guys gonna do a follow up to this video? I'm currently looking to do one and I'd love to see how yours has been doing.

[@ExploreTrekAdventure]

We do not have anything planned at the moment. What specific questions do you have?

[@darkskys163]

Just wanted to know how it has been working and if you guys wish you had done something differently. You also mentioned that you use the 200 watt inverter on the Jackery, but did not mention how. Do you somehow connect the DIY solar generator to your Jackery, or do you use it completely seperate from your DIY solar generator?

[@srkle222]

i found some times screws or nuts come loose from vibration, what i do is use Goop on the end of the threads near the nut or the head of the screw before i insert into the intended hole. easily comes off if needed.

[@largemarge1603]

Nylocks : a nut with a 'nylon' insert to reduce unloosening.

[@newupdatehourly]

Love this built the most so far on KZbin. Could you please guide me how you connect all the cable or if you happen to have the map? Thank you

[@jessejohns4783]

Thanks for the awesome video. Would it be possible to keep this charger connected to the battery continuously so it charges while your driving? Then only unplug it when you get to camp and hook it to solar?

[@ExploreTrekAdventure]

You could with a dc charge controller.

[@jessejohns4783]

@@ExploreTrekAdventure thank you for the help

[@matthewgreen2633]

I would also add a volt meter just so you can tell when the battery is getting low

[@ExploreTrekAdventure]

We picked a battery with a Bluetooth bms so we could check it on our phones but that would be a good option as well.

[@ThiCityProductions]

I am not sure if I missed it or not. I did not see any air vent gaskets on your box. With that battery being charged and used I would add those water proof air vents that way if your battery starts to expel any gases or heat for what ever reason your box doesn't blow up.

[@ExploreTrekAdventure]

Lithium batteries are sealed and do not require venting. Other types of batteries you would need to add a vent/fan.

[@mmatalk3817]

Turn the battery sideways you can add a 1000 watt inverter on top. 200 watt inverter is good adding a second inverter is great! It's better to have it and not need it, Then to not have it and need it.

[@Sugar_bug]

The battery alone is $460. By the time you add the other stuff and an inverter you might as well just by a 1000w solar generator

[@ExploreTrekAdventure]

It depends on your requirements but that might be a good option for some people.

[@nightstringers]

I want to build one of these, only use my 200 amp hour battery and my 2500 watt pure sine wave ac device. Things to add , wheels on the case for our aging back, lol

[@gregmckay666]

Excellent video. I've been thinking about building a very similar box and your parts list will be very handy!

[@ExploreTrekAdventure]

Thank you! Glad it will be helpful.

[@CarnivoreFrank66]

How long will this run a Cpap using a 12v adapter cord?

[@daviddelgado5954]

Loved the video! Do you recommend anything to charge it with 120v A/C? Thanks for the great content!!

[@kevinswinyer3176]

I have a question. I am planning on building a 12 volt power supply box, using a 12 volt Deep cycle Lead Acid Marine Battery, and a 2000 Watt Power Inverter. My question is this: for charging the 12 volt Deep cycle marine battery, I will need to use a 12 volt smart trickle charger. Can I plug that charger into the inverter while it is being powered by the same 12 volt Deep cycle marine battery that is needing to be trickle charged, or would I need to plug the 12 volt smart trickle charger into a regular wall outlet ?

[@largemarge1603]

@kev, A perpetual motion machine?

[@MrGsking12]

You should consider getting into 3dprinting and 3-D design You probably be pretty good at it.

[@ExploreTrekAdventure]

Funny you say that. We have been 3D printing for several years now. 😁 Its nice being able to make little adapters or replacement items for things.

[@MrGsking12]

@@ExploreTrekAdventure rightttt 😆😆

[@markvylonis]

does this build include charging the unit with household AC current ?

[@ExploreTrekAdventure]

Yes. Part 2 covers charging.

[@ItsEverythingElse]

Hard to find a terminal fuse block with an M8 battery connection. It's important to use the proper sized connectors.

[@alvarogaitan2529]

wow terrific job i waiting for part number 2

[@ExploreTrekAdventure]

Part 2 is already out and covers solar. DIY Solar Generator - Part 2 - AC & Solar Charging kzbin.info/www/bejne/nZvZfmaLjd90pas

[@DeFiDuke]

hi i want to use this diy technique to power my rv using the 50amp plug that I usually plug into the camp site power pole.. is this possible? similar to the new power banks that can do that example: oupes mega 2 , 3 and 5 .. thanks

[@liangzeng1806]

Great video. can You post video on adding 500 watt inverter? Appreciated

[@nicolafabris1041]

Great job Mister....many thanks for this kind sharing...very useful for my new project....Ciao Nick from IT

[@ExploreTrekAdventure]

Glad it was helpful. 😄

[@ZPDSurvival]

This is a cool design. Thank You.

[@ExploreTrekAdventure]

😀

[@tsk1979]

some 12V equipment can be sensitive to 14.4 of LiOn. Maybe put a 12.4V stabilized circuit somewhere

[@aimlessendeavor2]

100ah seems a bit overkill considering it’s 2 12v sockets and a usb port.

[@ExploreTrekAdventure]

It is primarily used to power a 12v fridge/cooler while we are camping.

[@MattiePie-m5u]

also, if you were to wire an inverter into this, where would you wire it in relationship to the kill switch and fuse box, would it be going into the fuse box??

[@jonnyfish76]

No. It would be wired to the battery.

[@robertbash8163]

How much are we talking about.?

[@MattiePie-m5u]

Hey, Curious about why you only put a terminal fuse on the positive and also a fuse box. Is that not redundant? I do like how it simplifies the wiring process.

[@largemarge1603]

Semi-retired Aircraft Mechanic A&P here. I install a fuse or circuit-breaker on any electric source: * battery * photovoltaic * alternator/generator... ... to protect the cable.

[@gilbertwalker1233]

What are you using to monitor your battery?

[@ExploreTrekAdventure]

The renogy battery has a built in BMS that we connect to via Bluetooth.

[@LocdnessMomster]

What would you do to keep a monitor on the batter level and if you went with a larger batter like a greater that 500ah battery, would anything need to change like bigger cords or different fuse box?

[@ExploreTrekAdventure]

We chose a battery that has built in Bluetooth bms so we can monitor the battery levels from our phone.

[@GoFlyPix]

Cool build man! I got confused at the end tho…when you picked up the solar cable connector wire you said you will get an Anderson flush mount then wire that to the fuse panel block. Don’t you need to run the solar wire to a charge controller, then from charge controller to battery?? Which I didn’t see at all in the video.

[@ExploreTrekAdventure]

Make sure and watch part 2 which goes over the solar. We went with a solar suitcase which has the charge controller built in. DIY Solar Generator - Part 2 - AC & Solar Charging kzbin.info/www/bejne/nZvZfmaLjd90pas

[@Tropiccafe]

QUESTION.....Will 2 of those 12 Volt Renege batteries fit into that box??

[@ExploreTrekAdventure]

No. One battery takes up most of the box.

[@ARElectric]

Awesome build, would adding a couple more batteries in series be fine with this configuration?

[@ExploreTrekAdventure]

You should be able to add more batteries. Just check with the battery manufacturer to see the recommended way to wire them up.

[@Christoph.403]

If you could post a parts list that would be a huge help. Thank you in advance

[@ExploreTrekAdventure]

This link will take you to our amazon storefront which has all the parts listed and the current prices. www.amazon.com/shop/exploretrekadventure/list/11SOVYYB87DQ1?ref_=cm_sw_r_cp_ud_aipsflist_aipsfexploretrekadventure_7WCJ4R8TQXAHCN58Z626

[@Christoph.403]

@@ExploreTrekAdventure perfect thank you !!

[@jcoats5529]

How about adding a dc to dc charger so you can charge the battery shine driving? A 12v charger is way to slow

[@ExploreTrekAdventure]

You definitely could.