Cheap PSU Mod

thingiverse

UPDATE 3/18/2019 Warning: Some stackable banana plugs purchased on Amazon have an excessive gap between egg beater contacts and shaft, likely designed to minimize rejection rates during mass production. When plugged in, the entire assembly can easily spin due to poor connection, resulting in resistance. Resistance leads to heat buildup. Heat leads to thermal runaway, which can cause a fire. I recently encountered a power lead that melted at the connection due to excessive heat. Fortunately, the melted plastic pushed the fitting aside, restoring contact and preventing further damage. Removing the melted plastic from the connection was a challenging task. To avoid this issue, check the joint for proper connection before using it. UPDATE 9/8/2017 I discovered an excellent connector option for this mod, perfect for those on a tight budget. The stackable banana plug from Tayda Electronics is a great alternative. Simply leave the PSU wires long and solder on these connectors to create instant banana cables. For a more robust version, I uploaded a beefier design with its FreeCAD file. Please note that I have no affiliation with Tayda Electronics, but their products were well-packaged and reliable. My quick-and-dirty bench power supply is made from an ATX power supply, following RepRap's instructions and warnings for converting PSU to a bench power supply. This style is perfect for temporary use due to its ease of construction and low cost. To assemble this setup, use inline fuse holders and cut banana clip lines (minimal cost). If you trust PSU voltage protections, you can skip the fuses. The clip acts as an insulator, allowing you to use the back of the banana cables for male connections or simply pull and unwrap the cables to attach to female banana connections. The spacing of the banana posts should accommodate dual banana plugs, ensuring a secure connection.