A family member recommended I show some of my projects, this is my first, there are some missing but simple steps as I deconstructed my case to create a basic instructable. I used some nicer components to build the case but simpler substitutions can be used.
Step 1: 1. Basic Rigid Case
This is a 22" Rigid Organizer Case, purchased at Home Depot for about $30 The 6 side organizers have been removed.
Step 2: 2. Drill Holes in Dividers for Cable Routing
Using a stepped drill bit, large holes drilled for running the power cables case.
Step 3: 3. Optional Additions
Using a stepped Drill Bit, 3 holes drilled above the handle for two 12v sockets and one Volt Meter.
Step 4: 4. Running Power Wires
This is a combination of steps, what you see here is a wiring for the two 12v sockets, and volt meter in the front of the case.
In the back of the case there is wiring for a power inverter using ring connectors M6 if I recall right. Additionally 2 sets of cables for duel batteries.
All is wired into a fuel block and grounding strip, This is a mid priced option, other options would be a Blue Sea fuse block with ground as a higher priced option or an inexpensive option could easily be a couple of 1/4" bolts with 1/4" nuts to separate the connections, 1 for positive and 1 for negative.
Regardless of how you run the positive and the negative, please keep them separate as you do not want to short out the batteries.
In this case, I installed a Genius charging cable for my Genius 3500 Battery charger so I can recharge the battery banks when at home.
Step 5: 5. Batteries and Inverter
Here are the batteries and Inverter used in the case.
Batteries are each 12v 9ah sealed lead acid batteries
Inverter is simply a 400w Continuous Inverter.
Industrial Velcro 10lbs applied to batteries, inverter, and bottom of the case.
Step 6: 6. Batteries Attached
Batteries and Inverter mounted with Velcro
Power cables attached, Positive to Positive, Negative to Negative.
Step 7: 7. Options From Step 3
Optional Power Ports and Voltage Meter from step 3 connected to battery banks.
Again, Positive to Positive, Negative to Negative.
Step 8: 8. Final Steps
Here is the general layout of the case.
Step 9: 9. Laptop Power Cord Placed
Laptop power cord installed, Transformer in mid section, cord plugged into Inverter, power cord to laptop given some slack and place on left side of case (where my laptop plug is located).
Step 10: 10. Cosmetics
A simple foam pad was cut out to make a cover for the fuel block and majority of the wiring.
Step 11: 11. Cosmetics Again
Second foam pad cutout to cover batteries and other wiring.
Step 12: 12. Spare Battery Storage
Given the additional space in the case on the foam pad covering the main wiring, I used this space to hold my spare laptop batteries.
Step 13: 13. Final Product
Final product, Case complete. During this project, you probably have seen a foam pad attached to the lid, the lid has an insert from the factory that is easily removed with a flat head screwdriver from the bottom, this was hot glued into the lid and provides a good cushion and support to hold my laptop in place without crushing it.
The batteries with Testing have powered the Laptop for 7 Hours while streaming netflix at full settings for maximum power draw. I stopped at 7 hours but given the voltage of the batteries in the case, it could have gone for an estimate 1-2 hours more.
Participated in the
Power Supply Contest