Do-It-Yourself Battery Pack 1 Page
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Table Of Contents Introduction... 3 Safety Precautions... 5 Step-by-Step Instructions for Creating a Battery Pack... 6 2 Page
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
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 24-31 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
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
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
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
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
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
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
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