DIY 24v 200ah Battery Box

[natefxx]

Making a box for my DIY 24v 200ah lifepo4 setup. Looking for feedback and ideas on how to finish it off. This will be mounted to my camper van floor

Bottom is 3/4" ply wood w/ 3/4" of packing foam on top, sides are 1/4" ply w/ 1" aluminum angle on the edges (1/4" ply is tripled up on the top 1" of box) with 1/2" polyiso on the inside (holds cells very snug). Lid is 3/4" plywood with lexan in the middle..

Plan is to secure lid with latches on 2 sides (no hinges due to mounting location). Am still undecided on how to run the 2awg battery cables to the inverter. Considering adding terminals to the lid or notching side of the lid and running cables through it.

Would love to hear what you all think!?

 

[Chris61]

Looks good, I'm making one very similar, 8 cells in a row, 12mm sides and bottom, 18mm ends, all formply. I have lined all sides and bottom with 2 sheets of 5mm plastic corflute, creating 10mm of insulation, but I also to hopefully circulate heat from a heat pad under batteries up through inner layer. Don't know how successful it will be, but I am hoping it will work. A couple of handles at each end to make it easy to lift.

 

[natefxx]

Looks good, I'm making one very similar, 8 cells in a row, 12mm sides and bottom, 18mm ends, all formply. I have lined all sides and bottom with 2 sheets of 5mm plastic corflute, creating 10mm of insulation, but I also to hopefully circulate heat from a heat pad under batteries up through inner layer. Don't know how successful it will be, but I am hoping it will work. A couple of handles at each end to make it easy to lift.

thanks,

I just added some handles to the exterior of the box. The straps in the picture are under the cells, it was the only way to get them out without tipping the box over.

 

[Chris61]

thanks,

I just added some handles to the exterior of the box. The straps in the picture are under the cells, it was the only way to get them out without tipping the box over.

I have made it easy to unscrew one end, all other pieces were glued and screwed

 

[Steve_S]

Similar to how I built my boxes for 24V/280AH
I used a Piano Hinge for the top and installed two handles on each box.
I ran 2/0 Cable from the cells to Batt Terminals (shown in my image). 5/16 Lug on the cell side as the bolts are M6 and 3/8 Lugs for the terminals.
The length of the 2/0 Excelene wire are Equal to prevent any variations.
* I use a Chargery BMS which sits on the outside face so that installation is a bit different.

My BOX


With 280AH Cells in place and wired for BMS.
NOTE: "Orange String" with green laying over top of cells is a pull string so I can pull 4 cells in a block out if required for maintenance or whatever.

 

[Chris61]

Photos of my battery box with one showing the plastic corflute to be used as insulation. It is still being made and has no lid as yet