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Thanks! The 2x4 isn't my idea. I saw the idea in another instructable or from a Make: post. To hollow it out, I used forstner bits to take out the bulk of the material, and then chucked up a router bit that I borrowed and put it in my drill press to get the area flat that the solar panel sits on. For the I/O sections, I used the forstner bit to make the initial hole, and then followed up with a small chisel. As far as the weight goes, I don't think it adds much for the plate/bolt route. It is only 1/16" aluminum and a #10 bolt. I also like it being more on the heavy side. It makes it seem more like an ordinary 2x4 and it leaves the user wondering as to what is on the inside.
I went a slightly different route with mine. Instead of a laser cut or 3d printer closure, I went with a hollowed out 2x4. I also made it so that the battery is removable and made a custom battery holder by way of the bolt to the left of the battery. On the backside of the "lid" for the battery is a metal plate that closes the circuit from the battery to the bolt. There is also a bolt with a spring on the backside of the battery to give pressure to the metal plate on the lid, ensuring connectivity. Additionally, I added a micro usb to the power input as those chargers are more common than the mini usb that comes on the charger module. For a finish, I went with a paste wax finish to give it some protection, but to try to keep it as natural 2x4 looking as possible.
On a side note, what's the purpose of the on/off switch? I added it to mine as you had one in your design, but I'm not really sure of the purpose. I noticed that the boosting circuit has a small LED when the switch is on, but other than that, there wouldn't be any power draw when there is no device plugged in. Otherwise, when you have a device plugged in, you would want it on all of the time to power the device.
Since the TP4056 has a micro usb, and usb transmits 5V, could you not directly wire the output voltage of the micro usb receiver to the 5V input of the TP4056 and use a micro usb cord for charging, therefore eliminating the need for the DC-DC booster?
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