DIY Flight case style battery box build

Luk3jay

Solar Enthusiast
Joined
Jun 20, 2021
Messages
37
Hello! I thought it's about time I give something back to the forum.

I searched high and low for DIY battery boxes, but couldn't really find anything I liked.

I'm in the process of making my own. in the style of a flight case. I've gone for the rugged industrial look.

I'm no carpenter or joiner by any means, so this is very much a DIY build! I've used 9mm ply, M6 Tee nuts, and M6 bolts and washers with some 300x300mm aluminium angle on the corners.

It's not finished yet, but I'm pretty happy so far and will update as it nears completion.

Test fit and first design.
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photocopied the underside of BMS to get an accurate template for the holes.
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Cut and attached a larger sheet of aluminium to allow for mounting the BMS
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Rivnuts installed into aluminium angle to mount the BMS
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Newly designed box construction with aluminium corners.
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Test fit of Cells (note the box is upside down)
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Installing rivnuts into the corner brackets. these will allow me to install the 'feet'
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Feet installed onto bottom brackets.
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BMS with Cell negative connection and plenty of heat shrink to insulate the terminal.
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That's all for now. I need to wait a few more days for the cells to top balance, then I'll install it all, fit the anderson plug, shorten the height, fit the top, and start using it!

Constructive criticism welcome. I think I've thought of everything but other suggestions and ideas won't hurt. I'll update the post as I complete it :)
 

Luk3jay

Solar Enthusiast
Joined
Jun 20, 2021
Messages
37
Well, It's finished! (pretty much)

M6 threaded bar through some 20mm plastic conduit used as a stopper for the cells (not that they need it as they're very tight in the enclosure)
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Cells connected, active balancer fitted and wired, BMS monitoring cables connected
(Note: the metal you see at the sides is the BMS mount. the perspective makes it look very close but there's actually over 10cm gap between the cell terminals and the Aluminium angle)
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BMS Mount fabricated and ready
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BMS Fitted and Main battery cables connected and ready
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I decided to make the Lid aluminium 'lip' as one continuous piece which required very careful measurement, marking, and cutting. I used a grinder to cut and made the cut slightly off where it needed to be in order to use a file to get the end bit. It's not perfect, but I'm impressed with the result!
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I used a clamp with a thin flat edge to bend the material around.
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Lid fitted and anderson plug half done
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WindWizard

Solar Enthusiast
Joined
Oct 17, 2021
Messages
165
Awesome job. It looks like it should function well. I would suggest watching the temperature inside to make sure it does not get too hot. The only other thing may be to put some wheels on that so you can roll it around.
 

Luk3jay

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Joined
Jun 20, 2021
Messages
37
Awesome job. It looks like it should function well. I would suggest watching the temperature inside to make sure it does not get too hot. The only other thing may be to put some wheels on that so you can roll it around.
Thank you. The temp has been absolutely fine with constant use after this post.

It will live in my van and only ever be moved in exceptional circumstances so the feet do just fine, but I agree that wheels would be good for a portable battery.
 

Luk3jay

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Joined
Jun 20, 2021
Messages
37
I added an RJ45 connector to the battery which allows me to connect my monitor screen(s) and/or Bluetooth module to adjust the settings. I wanted it to be quick release so that i can easily move the battery if needed.
 

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740GLE

Solar Addict
Joined
Apr 30, 2021
Messages
1,095
What display is that? I have to imagine it’s plug and play with that JBD BMS?
 

740GLE

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Joined
Apr 30, 2021
Messages
1,095
Also what’s needed to pull the aluminum plate off the MOSFETs without messing up the thermal heatpaste?

I like your ideal of securing the BMS via mounting a bracket to that plate
 

Luk3jay

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Joined
Jun 20, 2021
Messages
37
Also what’s needed to pull the aluminum plate off the MOSFETs without messing up the thermal heatpaste?

I like your ideal of securing the BMS via mounting a bracket to that plate

I left the original plate on and I only added a second thin plate on top of it. The screws were long enough to go through both pieces.

Thanks, it took me ages to come up with a solution I was happy with. I really wasn't keen on most of the other BMS mounting options I've seen..
 

740GLE

Solar Addict
Joined
Apr 30, 2021
Messages
1,095
I left the original plate on and I only added a second thin plate on top of it. The screws were long enough to go through both pieces.

Thanks, it took me ages to come up with a solution I was happy with. I really wasn't keen on most of the other BMS mounting options I've seen..

Ahh I see it now makes sense. Thanks
 
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