Surthrival Trailer Mark 1 Update #36 Creating a Lightweight Power Source for a HAM Radio

Hello Fellow Steemians!

Today I worked to create a lightweight portable Power Source for a ham radio system that will be installed in the trailer.

I began by cutting 3 custom copper bussbars at 2.5"lengths from a 1"x.25" copper bar. I marked holes @1.5" center to center and clamped the piece on the drill press. These busbars will allow me to create a 13.0 V battery bank from these Headway 38120 8AH LiFePO4 cells.

I drilled 2 1/4" holes for M6- 1.0x12 Machine Screws to join with the Headway Cells.

Using some electrical tape I wrapped the Headway cells a few times to hold them together. I connected the middle 2 cells on the + and - terminals and screwed them down tight.

The cells were arranged so the polarity of the terminals alternate + - + - . Two more busbars were connected to the first 2 and last 2 cells. There should be a + and - terminal open at both ends. I have a bms circuit that I connected, but I still need to do some troubleshooting. This will allow the cells to be charged via a 100 watt solar panel.

I applied some lead free solder paste to some 12 gage stranded copper wire.

I was using non leaded solder which requires this paste applied for a proper solder joint.

I crimped and soldered ring connectors for the + and - wire terminals of the 13.2V battery system.

I screwed the ring connector into the negative terminal.

I then secured the + terminal to the battery pack. The opposite side of the wires were connected via male blade connectors to the + and - female blade connections of the ammo box.

I connected the + and - wires for the portable HAM radio to the appropriate screw down terminals and powered up the radio for a test.

Everything powers up well! I need to make some modifications to make the ammo box depth slightly larger to fit the 38120 headway cell battery pack. I also need to troubleshoot my BMS system and reconnect this to allow for proper charging of the headway cells.

Thank you for your time if you gave my update a read!

Yours in liberty toward a brighter future, may the great creator bring peace and joy within your hearts, Greg @makinstuff