Charging Station Suitcase




Introduction: Charging Station Suitcase

A suitcase charging station that is a step up from sticking a power block through a hole, this station has two built in double USB power points.

This Instructable deals with mains power and will kill or horribly injure you if you don't know what you are doing. So unless you are a licensed electrician, don't do this yourself.

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Step 1: Bits and Pieces

An appropriate sized suitcase (box, tin, whatever). For this project we bought an old trumpet case from the recycling centre for $10.

2x wall mounted double USB power points.

240v 10amp power cable. We got a nice cloth covered cable plus a little bit extra to join the power points.

Mains male plug.

Hunk of nice wood to mount everything on to.

Assorted electrical tools and tape.

Step 2: Prep

If you are using cloth covered cable, make sure you wrap some electrical tape around it before cutting or stripping (otherwise it splays out like a before shot in a hair product infomercial).

Strip back enough wire on both ends to comfortably fit in the plug. I had to go back after the photo and redo it.

***be very careful to check that you haven't inadvertently cut the insulating plastic on any of the wires - this is one of those things that leads to horrible injuries or death***

Connect your plug making sure all the wires have a good firm connection.

Strip out your chosen case and scrape/sand it back if necessary.

Step 3: Cut Out the Mounting Board

Cut your board to size so that it fits snugly in the case.

Mark out where you want the power points and test that all your devices and plugs will fit in the position.

Drill a hole in the middle (or a corner if you are confident not to screw it up) and use a jigsaw to cut out the spaces for mounting to sockets.

Test the spaces out and check the alignment of all the pieces several times as you go.

When everything fits and lines up, use a router (or Dremel in my case) and cut a line just deep and wide enough to run a cable between the two points.

Step 4: Lining the Case

If you had to strip out the case this is where you cut thin sheets of foam (such as a yoga mat you used once and will never need again) and use spray adhesive to stick the fabric of your choice on.

Let it dry overnight with weights on it, then fold over the excess and repeat.

Once it is all dry use the spray adhesive to stick it in the case using offcuts of wood to clamp it in place while it dries.

Step 5: Putting It All Together

Drill a hole through the back of the case that will fit an appropriate sized cable gland.

Wire together the two sockets and the mains plug taking particular care to match up the connectors to the matching position on the plug.

Use furniture brads to nail the mounting board in position.

Plug things in and test it out!

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    6 Discussions


    4 years ago

    Thanks nwonharp - that's a good idea!

    At the moment I have a specific place for it that works best sitting flat, but any future change would have been better if I did as you suggest.

    The other idea was was to use an old computer power plug with a built in fuse so I could detach it, but that is a future project (along with a safety power breaker which really should have been the first thing I did).


    4 years ago on Introduction

    Good build , it looks nice ! I'm glad that you included a safety warning . People without the proper training should not try this . Looks like you have plenty of room inside the case . You could also put a charger for a cordless drill-driver battery , or other things . Some batteries require ventilation while charging , so you may need to leave the case open .

    A suggestion , if you route the mains cord through the side of the case rather than the bottom , the case could sit up on it's feet when being stored .

    Cheers , take care , and have a good day ! 73


    4 years ago

    Thanks Stephen - that's why it comes with the warning that only a licensed electrician should attempt it - they have the training to judge their own safety. Everyone else will die screaming.


    4 years ago on Introduction

    You do realise in australia any form of diy electrical is dangerous and illeagal and if someone gets this wrong and dies you will be held partially accountable. Just letting you know.


    4 years ago

    Looks super cool man


    4 years ago

    This looks quite useful! Awesome build.