Makita 18V Power Supply

prusaprinters

This is a full build of a power supply based off Volan's original design, but with significant modifications.  The adapter now has a bolt thru to M5 threaded insert, longer brass contacts, and enlarged bay area.New portion is the case meant to house 2 LM2596 buck converters, allowing 2 voltage outputs (I chose 12V and 5V).  Note, I made the case top with 2 simple locking lugs with only a screw to secure, this would make access easy if you need to reset the voltages as desired.Overall build uses the following:2 - LM2596 buck converters (note the spacing of mine and most will have bolt holes that are 6.5mm from short edge and 2.5mm from long)5 - 4mm long M3 threaded inserts (4 -case top, 1 adapter)2 - 9.5mm long M5 threaded inserts (sides of adapter plate)4 - 8mm M3 bolts (for attaching buck converters to case)1 - 12mm M3 bolt (for attaching case to adapter)2 - 12mm M5 bolts to secure brass inserts4 - Banana Plug Jacks2 - brass contacts (mine where .85 mm thick, should work well with upto 1mm) For brass contacts, use the Test Blade file to mark the brass for 2 items, and the location of the 5mm hole.  Note the absolute accuracy isn't necessary, just roughly 10mm x 58mm x .85mm.  For brass final piece, just make sure the hole lines up with the adapter plate bolt hole, and the length does not exceed the front guide.  NOTE, use the open access holes in adapter to make sure the threaded inserts are not fouled with plastic.  this method also allows clean access to secure the first brass blade, the other will either have to use an a short allen key or ballnose key.Assembly pictures shown, but this has more to do with your wiring choices, although the use of the Wago's to allow quick connection was useful after passing through the wires through the adapter plate for final assembly.  Note, you can pre-set the voltages of the LM2596 before install, but I found it to be easy to tweak the resistor pots after the fact.Included in the files is an alternate case top which is a bit roomier, as it is the full width of the adapter plate.  As mentioned also included is a test blade for marking and drilling brass contacts.  There is also a full plate of the thin tower (as in picts), adapter and test blade.  As was supplied from Volan's set, I have included the .f3d and .step files as the case top can be modified.