hardtop
New Member
Why did that other box catch on fire?
Rethinking my battery box
- Thread starter SparkyJJO
- Start date
Which box? The most recent big fire thread wasn't in a box. We really don't know exactly what happened.
So some boxes arrived. They're a bit heavy, which is good (and bad, if I ever have to move them after assembly lol).
Nice and roomy. Remember these are the 24x16x12. The steel is plenty thick and sturdy.
Some interior measurements real quick, without and with the mounting plate.
A pair of my EVE230 cells, for reference. I'm planning on lining the inside of the box that makes contact with the cells with neoprene to insulate it from shorts and give a little cushion. Box will remain flat on its back and the lid will be on top for access. I'll need to do something to keep the cells in nice neat rows. There will be separator sheets between every cell also.
Nice and roomy. Remember these are the 24x16x12. The steel is plenty thick and sturdy.
Some interior measurements real quick, without and with the mounting plate.
A pair of my EVE230 cells, for reference. I'm planning on lining the inside of the box that makes contact with the cells with neoprene to insulate it from shorts and give a little cushion. Box will remain flat on its back and the lid will be on top for access. I'll need to do something to keep the cells in nice neat rows. There will be separator sheets between every cell also.
Looking at this again I'm wishing I had a good way to cut steel plates nice and square. Would make life much easier if I had that ability. Was thinking maybe I could use some L brackets and something like unistrut or square tube or angle iron to provide some rigidity, and figure out how to countersink screws so the heads are flush and don't push into the cells through the insulating foam.
But in the end, I'm really not sure how best to modify these. I don't want to use wood in them, but I have near zero metalworking skills and a lack of tools. I didn't think this through very well.
Maybe I'll end up using these as connection/busbar boxes, and will get some Luyuan boxes if they can be made to work with my 230Ah cells without much fuss or extra time. Not sure yet. I just need some time to sit down with the boxes and cells, and do some brainstorming.
But in the end, I'm really not sure how best to modify these. I don't want to use wood in them, but I have near zero metalworking skills and a lack of tools. I didn't think this through very well.
Maybe I'll end up using these as connection/busbar boxes, and will get some Luyuan boxes if they can be made to work with my 230Ah cells without much fuss or extra time. Not sure yet. I just need some time to sit down with the boxes and cells, and do some brainstorming.
Bob142
Build more, learn more.
I’m all in following you down this rabbit hole. I've got boxes on the way and just about zero metal fab experience. I figured I'd buy something like this inexpensive 18" metal brake from Harbor Freight, and find some suitable sheet steel I can cut and bend into restraining brackets that I bolt to the sides of the electrical box. If nothing else, I get to dip my toes into a DIY metal work project to see if that's something I find worthwhile.
Brett V
Mad Scientist
Tulex did a beautiful build with a similar box.
diysolarforum.com
First of two battery builds
Sorry the pictures are blurry, my phone just sucks. This is a standup case with 16 304ah cells. Cabinet is a knockoff of Vevor 16 X 24 X 12 deep. Seplos 200a bms, 300a T-class fuse, and BEP Marinco disconnect, which has been confirmed safe to use on a 48V system. Not in the pictures is...
diysolarforum.com
Yep I just have smaller cells so they don't fit as snug. I also do not want them on their sides (I know they say it is OK I just don't like it).
I'm thinking I can simply get some 16 gauge sheet metal at the store, cut it to length (maybe an ugly edge but w/e), and use some L or C channel to reinforce it and attach with L brackets and screws.
The mounting plate has nuts in the way to space the cells the way I want, but if I take the plate out, there's still little bumps on the bottom of the box. Wondering if I can find a way to hammer them flat to cover over with my neoprene foam.
To do this week is to get some time to really delve into this, use some cardboard as a mock-up to help me visualize things, and go from there. Due in part to some less than positive feedback from the wife on the cost of the Luyuan boxes (not so much the individual cost, but then add up the shipping too) this time around I should probably just make these work. I can do it, just takes me some time.
I'm thinking I can simply get some 16 gauge sheet metal at the store, cut it to length (maybe an ugly edge but w/e), and use some L or C channel to reinforce it and attach with L brackets and screws.
The mounting plate has nuts in the way to space the cells the way I want, but if I take the plate out, there's still little bumps on the bottom of the box. Wondering if I can find a way to hammer them flat to cover over with my neoprene foam.
To do this week is to get some time to really delve into this, use some cardboard as a mock-up to help me visualize things, and go from there. Due in part to some less than positive feedback from the wife on the cost of the Luyuan boxes (not so much the individual cost, but then add up the shipping too) this time around I should probably just make these work. I can do it, just takes me some time.
Brett V
Mad Scientist
Is there enough space to fit a plastic cutting board in the bottom? I’ve used them in place of 1/2” plywood and they work well. Easy to cut and inexpensive. If you’re a Sam’s Club member, you can get a 15” x 20” board for $9
Yes there's plenty of room for that. I would just have to figure out how to attach it. I don't expect to move these boxes much, but reality is they will need moved if we move to another property sometime, so I'm planning ahead for that a bit.
Which, on that note, I'm thinking of buying 4 of these for each box, perhaps. Make it easier for a couple people to lug them out if/when the time comes to do that.
Which, on that note, I'm thinking of buying 4 of these for each box, perhaps. Make it easier for a couple people to lug them out if/when the time comes to do that.
Brett V
Mad Scientist
16 of the 230 ah cells will be close to 100 pounds. Add the weight of the box and whatever else is going in there to get a rough estimate of what you will be lifting.
42OhmsPA
What's in a title?
Give your local steel suppliers, machine shops, or weld shops a call... You could also used my screwed up logic, it's justification for new tools.
Tulex
Solar Wizard
Yeah, my boxes with 304s is over 200 lbs, had to shimmy them into place.
SilverbackMP
Solar Addict
- Joined
- Apr 4, 2022
- Messages
- 967
I added similar to most of my (plywood) boxes. I would trust them to lift a 200+ lbs box, but the work ok in wiggling the boxes into their steel cabinet home.
Edit: I just used one on each end. Two on each end I might trust a little more as long as they are both used when lifting.
Ok I can't seem to find a good answer on this. How thick should a compression plate be? Is the 16 gauge steel of the box good enough? I was going to press the cells up against the end of the box (with an insulating layer of course). I am not looking to squeeze the crap out of these cells, juat hold them in place.
ArthurEld
Solar Wizard
The premade boxes have stiffeners on the compression plate. Without stiffeners, the plate would have to be thick. Probably more than 1/4" thick.
ArthurEld
Solar Wizard
.063 thick
Ive got one of those metal brakes, had it for years now. Probably wont help you. (Read the one star reviews, theres a lot of them) First off you need about half a dozen stout C clamps of various sizes to use it. Secondly its good for MAYBE 20 gauge steel at best. Anything you could bend with it you could probably bend over the end of a work bench with a couple of C clamps and a hammer.
Theres a metal supply place in my city called IMS or industrial metal supply. Theyre a chain might have one near you or something similar. At IMS they have rems in aluminum, steel, and stainless, in all shapes and sizes and theyre cheap. If you dont find what you need in the rem pile theres open stock.
Industrial Metal Supply Co. | Metal Made Easy
www.industrialmetalsupply.com
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OffGridForGood
Catch, make or grow everything you can.
I have had good responses in the past from a local HVAC shop - when they are not busy they will brake-form sheet metal stuff for me that is too big for me to do with my own tooling. They seem pretty reasonble on the costs. Can't hurt to ask.
