12V Connector Box

thingiverse

This is the perfect fit for a 12v connector box that accommodates panel mount connectors such as Anderson PowerPoles, 12V cigarette lighter sockets, and 12v USB adapters. You can mix and match these panel mounts to suit your needs. If you're unsure about electrical safety, fuses, or wire gauge, this project may not be for you. Take the time to learn some basic electrical wiring and safety principles by getting an amateur radio license and seeking guidance from an Elmer. To begin, I attach a one-foot-long Anderson PowerPole pigtail through the small rectangle hole on the side of the box. You can secure it with a zip tie inside the box for strain relief, preventing the wire from pulling on internal connections. This is also a good spot to install an inline fuse (see cover variant). Next, connect the switch and fuse in series to the (+ red) & (- black) banana posts using the battery pigtail wire. Then, connect all panel mounts in parallel to these banana posts (See schematic diagram). To optimize cable length, mount higher current devices close to the banana posts. Lower current 5V USB and voltmeter devices can be installed at the far end. Remember to use sufficient gauge stranded copper wire that can handle the current load plus a safety margin. Typically, you'll need 12-14 gauge wire. Research your specific needs based on battery, wire, fuse, and load requirements. Never omit the series fuse. Batteries can produce extremely high currents when shorted, making it essential for safety. It's better to blow a fuse than risk damage from overheating. You could also consider using a circuit breaker instead of a fuse. To build this project, you'll need: 1. 100% infill with ABS (PLA works but may warp in sunlight) 2. #8 x 3/4" Pan Head Phillips Sheet Metal Screws The first prototype had three holes, but I later modified it to a four-hole configuration for better fitment within an ammo box with the battery. Once finished, I'll post photos of the updated design. This project was inspired by Tony W6TNY's original battery box design. The clear bottom connector box was showcased at SOARA meetings (www.soara.org). The benefits of this connector box are: 1. Expensive panel parts become more portable between batteries. 2. The connector box can be stored inside an ammo box, keeping everything clean and protected. 3. Ammo boxes with batteries can now stack seamlessly. 4. Electrical wiring is safely enclosed, reducing the risk of damage or snags. A second cover variant removes holes for switch and fuse, using an inline fuse in the pigtail instead. Unplug at the pigtail to turn off power. The banana post holes have been relocated to provide more room for wiring terminal rings. Be aware that some taller panel mount devices, such as 12v lighter sockets, may require 90-degree spade lugs due to limited box height. 73, Ed, WA6ED