Dewalt Power Box

thingiverse

v2 Box uploaded to resolve an issue with the XR Series batteries ------------------------------ I present you with a Dewalt Power Box that I'm using for ice fishing. The Dewalt Battery mount and stress relief was sourced from https://www.thingiverse.com/thing:4812733 Parts list: 3 each Eagle Eye LED lights: https://www.amazon.com/dp/B00MVMRS6O/?coliid=I1YX6SUD0MZ2GA&colid=1C1E9TNFXI8T5&psc=1&ref_=lv_ov_lig_dp_it 1 each Buck Converter to reduce 20vdc to 12vdc for LED lights https://www.amazon.com/dp/B01MQGMOKI/?coliid=IIGMU8C6GG4XJ&colid=1C1E9TNFXI8T5&psc=1&ref_=lv_ov_lig_dp_it 1 each Digital Low Voltage Protector to protect Dewalt Battery (set to 15.3 vdc) https://www.amazon.com/dp/B07929Y5SZ/?coliid=I3HRFETUK6U1CR&colid=1C1E9TNFXI8T5&psc=1&ref_=lv_ov_lig_dp_it 5 each lighted toggle switches https://www.amazon.com/dp/B08Q3WJW8Q/?coliid=I2HDTKQKMLJ50M&colid=1C1E9TNFXI8T5&psc=1&ref_=lv_ov_lig_dp_it 2 each DC power socket https://www.amazon.com/dp/B08SJM2G52/?coliid=IZZB1VAVBQWPG&colid=1C1E9TNFXI8T5&psc=1&ref_=lv_ov_lig_dp_it 1 each USB socket (or similar) https://www.amazon.com/dp/B08XWZRTT8/?coliid=I3H469RRCP5NOP&colid=1C1E9TNFXI8T5&psc=1&ref_=lv_ov_lig_dp_it 2 each inline fuse holders (USB input and battery output to low voltage disconnect) https://www.amazon.com/dp/B07FT7J2CS/?coliid=I1YZAMASV0TDNB&colid=1C1E9TNFXI8T5&ref_=lv_ov_lig_dp_it&th=1 Consumables: 16 AWG black wire 16 AWG red wire 5 amp fuse (2) male spade connector (2 for dewalt battery) female spade connector (lots of them) solder 4 M2x8mm screws 1 M3x6mm screw Printed with GST3D Black PLA+ at 215C nozzle, 65C bed, 30% infill, and tree supports. Print box face down on bed for best results. -------------------- Instructions below are subject to change -------------------- To assemble: 1. Insert all the switches, the USB socket, lights, and DC sockets 2. solder + (inline fuse) and - wires to Low Voltage protector (input and output) 3. Solder LVP output to buck converter input 3a. Connect LVP + and - to master switch. + output of master switch to buck converter 4. solder + and - wires to buck converter output and adjust output to 13vdc 4a. + output from Buck Converter daisy chains to all switches + input 4b. Daisy chain the - (ground) wires from the buck converter to all switches, leaving extra for add-ons, such as the lights and DC connectors 5. Crimp 2 male spade connectors on + and - wires from LVP input, and insert in appropriate slot of battery base 6. deleted 7. Start cutting red (+) wire in 2" pieces, strip ends, and start a "daisy" chain" from the master power output to the last switch 8. Cut black (-) wire in 2" pieces, strip ends, and start a daisy chain through each switch, then the negative of each accessory (lights, usb, etc) Once everything is wired, install the bottom (fish down) and use M2x8mm fasteners. Use a small M3 screw to hold the stress relief to the battery 'bottom' to keep the connectors from popping out ---RESOLVED with v2 -- A Dewalt 2AH battery fits very easily, but a 5AH or larger is a tight fit. I probably missed some steps, so ask away in the comments.