Do-It-Yourself Battery Pack

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Emory Harmon
6 years ago
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2 D I S C L A I M E R O F L I A B I L I T Y A N D W A R R A N T Y This publication describes the author s opinions regarding the subject matter herein. The author and publisher are not rendering advice or services pertaining to specific individuals or situations. For specific advice, or if expert assistance is required, the services of a qualified professional should be obtained. The author and publisher assume no responsibility whatsoever for the use of the information in this publication or for decisions made or actions taken based, in whole or in part, on the information in this publication. The author and publisher make no warranties, express or implied, regarding the information. Without limiting the foregoing, the author and publisher specifically disclaim and will not be responsible for any liability, loss, or risk incurred directly, indirectly or incidentally as a consequence of the use or misuse of any advice or information presented herein. Use this publication and information with good judgment and do the best you can in your particular situation. You agree to indemnify and hold the author and publisher, and their respective officers, directors, agents, employees, contractors and suppliers, harmless from any claim or demand, including reasonable attorneys fees, related to your use or misuse of this publication or the information contained therein. You further agree that you will cooperate fully in the defense of any such claims. Notice: As the purchaser of this electronic document you are permitted to store it and print it for your own personal use only. Otherwise, no part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise without the prior written permission of the copyright owner and publisher. It is illegal to make a copy of all or part of this publication for someone else, even if you do not charge for the copy. If you have purchased this book from anywhere other than OffGrid-Independence.net, including ebay, please report it to david@offgrid-independence.net immediately. C O P Y R I G H T Those who have received or purchased the guide are neither authorized nor permitted to transmit copies of this guide to anyone without written permission. Giving away copies to people who haven t paid for them is illegal under international copyright laws and will submit you to possible legal action. Therefore, the utilization of this file is limited to personal use only. T E R M S A N D D I S C L A I M E R By using, viewing, and interacting with this guide or the OffGrid-Independence.net website, you agree to all terms of engagement, thus assuming complete responsibility for your own actions. The authors and publishers will not be held liable or claim accountability for any loss or injuries. Use, view, and interact with these resources at your own risk. All products from OffGrid-Independence.net and its related companies are strictly for informational purposes only. While all at-tempts have been made to verify the accuracy of information provided on our website and within the publications, neither the authors nor the publishers are responsible for assuming liability for possible inaccuracies. The authors and publishers disclaim any responsibility for the inaccuracy of the content, including but not limited to errors or omissions. Loss of property, injury to self or others, and even death could occur as a direct or indirect consequence of the use and application of any content found herein.

3 Table Of Contents Introduction... 3 Safety Precautions... 5 Step-by-Step Instructions for Creating a Battery Pack Page

4 Introduction At least one battery pack should be standard equipment for anyone who desires to be prepared for any type of disaster or emergency where electrical power is disrupted. The battery pack should also be a go-to item for outdoor enthusiasts who need power in remote locations. Remember, a battery pack is a set of batteries with the same volts that is configured either in a series or parallel, or both, to deliver power to the intended devices, appliances, equipment, etc. to charge or operate them. With just a little equipment and few supplies, you can follow ten easy-to-do steps to create a battery pack that will serve you well, all within about an hour. Making a battery pack is not complicated and anyone can do it if the simple instructions in this report are followed. And just think about all the ways that you can use the battery pack for an excellent source of stored energy! 3 Page

5 As always, use safety precautions any time you are working with automobile batteries. There is more information about how to stay safe while working with batteries below, but be sure to gather your safety supplies when you gather your battery pack supplies and equipment. To get started, gather the following supplies: Plastic battery box (Group battery box) that contains a divider inside 12-volt automobile top-post battery. A top-post battery is one that has the terminals on the top of the battery. Wire cutter/strippers that can also be used for crimping Two top-post battery terminals with wing nut Two ring terminal One auxiliary power outlet kit One inline fuse holder 10-amp fuse Permanent marker pen such as Sharpie Drill with step drill bit. If you don t have access to a drill with step drill bit, you can use a drill bit and a sharp knife. Two butt splice connectors 4 Page

6 Goggles that seal around the eye area Rubber gloves that come up to the elbows Rubber apron Safety Precautions It was mentioned above that you should always take safety precautions when working with automobile batteries. Batteries contain acid and chemicals that can be flammable and extremely caustic when in contact with skin or clothing. Always wear safety goggles that are sealed around the eye area, rubber gloves that come up to the elbows, long, tight-fitting sleeves, closed-toe sturdy shoes, and a protective rubber apron when working with batteries. Do not wear baggy clothing. Do not smoke or have any open flames in the area, and work in a well-ventilated area such as a garage or shop with open doors/windows or a ventilation system. 5 Page

7 When working with batteries, also know what type of battery you are working with and the type of emergency first-aid care that should be administered if there is an accident. Keep an eye-wash kit and first aid kit and supplies in the area that you are working in. Always have a plan for an accident while you take precautions to prevent one! The steps for building your battery pack are simple, but follow the instructions carefully, and remember that you are working at your own risk! Step-by-Step Instructions for Creating a Battery Pack Step 1 When you open the plastic battery box, there will be a divider inside. Leave the divider in the box, and put the 12- volt battery inside. Adjust the divider so it is pressed against the battery. There will be some empty space in the box for the wiring, but the 6 Page

8 battery should be packed snugly in the box so it does not move around. Step 2 Take the battery out of the plastic battery case so you can mount the socket hole underneath one of the hoods of the battery case. This will provide the socket with an overhangshelter from the elements in the event of rain or snow while the battery pack is outside. Now, remove the socket from its package and unscrew the shell. Remove the bracket from the shell. Trace around the bracket with a marker and trace inside the bracket hole so you know exactly where to drill the hole for the socket. Be precise with your marking. 7 Page

9 Step 3 Now, you re ready to drill the hole for the socket. If you are using a step-bit, drill a circular hole. If you do not have a step-bit available, you can use a small drill bit and whittle the hole to correct size with a sharp knife. Step 4 After the hole is drilled, set the bracket inside the hole, put in the case, and attach the shell. Make sure you tighten the shell. Now, the divider is ready to go back into the box. Step 5 Remove the packaging from the inline fuse holder. Use the wire cutter to strip a short segment of the casing off the end of each wire. Then, twist the wires together. Repeat the same process for the other side of the inline fuse holder strip a short segment of the casing off the end of each wire, then twist the wires together. Both ends of the fuse holder are now prepared. 8 Page

10 Step 6 Attach a butt splice connector to each prepped end of the fuse holder. Make sure the wire is firmly inside the butt splice connector by twisting it in tightly. Use the crimper on the wire cutters to crimp the wires inside the connector. Connect the positive wire from the auxiliary power outlet kit to the other end of the butt splice connector, and crimp that side. This positive wire assembly is now ready to install to your battery pack. Step 7 Screw the positive wire into the center of the power outlet. The positive wire should be long enough, but check it before proceeding. Put the car battery back into the battery case. The positive wire assembly should reach the positive terminal. Stuff some of the extra wire into the space on the side of the divider opposite of the battery side. 9 Page

11 Step 8 Now, you can install the battery terminals. Take the wing nuts off the terminals. Check again to make sure that your positive wire can reach the positive terminal. Then, put an end crimp on the wire and attach a ring terminal. Firmly crimp the ring terminal and positive wire together. Step 9 Take the negative wire from the auxiliary power outlet package and make sure it is long enough to reach from the socket to the negative terminal on the car battery. Attach an end crimp and a ring terminal to the negative wire. Crimp them together. Attach the negative wire to the negative terminal and plug it into the outlet. Check your work before you continue. You should have a negative wire running from the outlet to the negative terminal, and a positive wire with an inline fuse holder running from the outlet to the positive terminal. If that is 10 Page

12 not the case, you need to go back over the steps and see where you ventured off course and re-do the steps. Step 10 Attach the fuse to the inline fuse holder. (A 10-amp fuse is recommended.) You can test your battery charge and measure output attach a multi-meter that is set to DCV; touch the red wire to the positive terminal of the battery, and touch the black wire to the negative battery terminal. Now you are ready to put the cover on your battery pack so it is protected from the weather and any small critters or children are protected from encountering it. The battery pack is now available to use for many purposes as an inexpensive and reliable source of power. And you have the knowledge and expertise to create additional battery packs as needed! Good job! 11 Page

Solar-Powered Battery Bank

Solar-Powered Battery Bank 1 Page D I S C L A I M E R O F L I A B I L I T Y A N D W A R R A N T Y This publication describes the author s opinions regarding the subject matter herein. The author and publisher