24V 1800 Watt Portable Charging Box

[WillJames]

Good god, that box is INSANE. Nice work!!

[Rick~K]

I really like the charger box. The whole setup is the nicely done.

[pctomlin]

Hey Will and Rick,
Thanks for the compliments on my charging box. It definitely surpassed my expectations from what I set out to do. For my needs it is perfect with some power to spare/share.
I am a little anal when I set out to build something and start to research what I want to do. I just looked at my bookmarks for this and I have 56 sites/threads saved. I am a much better builder than flyer right now.

[Rick~K]

Your Welcome Paul. I am plaining on building your box as close as possible. It will be a couple months before I need to have it finished, but its what I'm looking for. I'm joining a local club that has AC at the field so I'll have a good area to change.

Thanks for all the information!
Rick

[pctomlin]

Here is a PDF of the cutting template I made for installing the PSUs into the tool box. I set the line at the bottom even with the bottom of the metal tool box and then drilled and cut the holes.

[Rick~K]

I have it DLed and saved with the photos, along with the doc's.
Thanks Again!

[Rick~K]

I found a good place to buy the C19 PS cables, sizes from 1'-25' long. I got 3' for mine, tested the PS's today for DOA's and all are fine, got the box and ready to start the project soon. This box is going to look great on the flight line at the field!

Thanks Paul!

here is a link to the site:
http://www.cables.com/category/cable...-125-volt.aspx

[Jeff_Barrett]

Just working on mine right now as well.

I bought my cables from www.infinitecables.com .... they were cheap too!!

Did you use 12AWG or 14AWG for your connections?

[Rick~K]

Originally Posted by Jeff_Barrett

Just working on mine right now as well.

I bought my cables from www.infinitecables.com .... they were cheap too!!

Did you use 12AWG or 14AWG for your connections?

I used the 14AWG

[Jeff_Barrett]

About 5-8 feet of each will do you think?

I've got the PSUs and I'm waiting on the power cords - I should have them tomorrow.

I'm heading out to my electronics specialty store to pick up the terminals, bullets, cable, and power switch this afternoon.

[Rick~K]

I think that would be fine but it depends on how long you'd like them, I choice 3' because at out field we have tables and if I need more I'll run a power strip.

I went by my local electronics supply store yesterday, this was one of the best stores of its kind I'd ever seen. But its now out of business.

[Jeff_Barrett]

I was very disappionted today with both of my local electronics specialty stores (Active Components and Tip Top Electronics). Both specialize in component level parts, and neither had the stuff I wanted / needed.

Looks like I'm going to puchase these items online. Thankfully, one of my suppliers has both items (I feel stupid for not checking earlier and adding it to one of my inventory orders!)

I thought I had found the suitable enclosure as well, but when I went back and measured, I realized I had measure the wrong dimensions and the tray supports are too low in the tool box. Back to searching some more ....

... on another note, I was finally able to test the PSU's tonight as my cables arrived. I'm impressed with how quiet they are. Voltages are good across the board.

[atv223]

My set of Dell 6650s came in today. I have to hurry up and check them since I only have 7 days to tell the eBay seller if there is a problem. I'll have to rig up a cord for the them. The funny thing is my only heli at the moment is an mSR. LOL. I got so exited by Pctomlin's build and I found a good deal on the PSUs I had to jump in! I suppose I am now committed to the hobby!

[pctomlin]

Don't worry,......... it only gets worse

A important update for a box to hold the PSUs. DoctorJ is building a charging set up and let me see some of the preliminary build pictures, very sweet set up. Apparently Lowe's has a new Kobalt tool box that fits these PSUs pretty well from his pictures, wish they had this box when I built mine. This one has smooth sides instead of the treadplate like the tool box from HD. Here is the info for the tool box with thanks to DoctorJ for finding and sharing it.

Kobalt Model number is SGY-BOX1A, Lowe's item Number #0132778

[Rick~K]

I haven't cut mine yet so I'll drop by and have a look, I kind'a like the looks of the tread plate box. I was looking at the diamond and see a challenge cutting it.

[pctomlin]

The treadplate tool box is a little bit challenging to make the cut out. The template has to be layed out on the inside of the box to find the flat areas to drill the holes if you plan on using the screws for the fans to hold the PSUs to the end of the tool box, I also double sided taped the PSU to the bottom of the tool box for added security. I then taped the template to the outside of the tool box using the holes as a guide to line it up and used my Dremel to cut out the openings.

[Rick~K]

Does the template allow for the thickness of the double sided tape? I was thinking about that before cutting it.

[pctomlin]

That is what the line under the template is for, it is a cut line with the little fudge factor added for the double sided tape so it could be placed inside the tool box to line up the holes as best as I could.

[Rick~K]

I checked out the Lowes box today, I still like the HD box better so I'm going to go ahead with it. I recieved the PS power cords so I'm going to remove the handles this weekend. I hope Sunday to cut the end of the toolbox at work. I'll do pictures as I build it and post them.

[sockrim]

What would happen if you turn off the 12v server before the 24v server??