A VARIATION ON A THEME
I made a VERY similar "Crate" Solar Generator several weeks ago. I agree; fun build, cheaper than a commercial suitcase Solar Generator of similar capacity, a very useful & quiet portable 120v power supply. By putting the separate parts together, you can change them out if they fail. Just like anything else, there are limitations; battery size being one of them.
I used a Lion Energy LiPo4 105Ah battery, an ePever20a charge controller, (I'm partial to them), and a 1500w pure sine wave inverter. Since placement of the charge controller in the crate prevented being able to view the screen on the charge controller, for monitoring purposes, I used a MT 50 remote monitor. I have too much trouble with the blue tooth phone aps, so I went this way. I had the crate, the battery, 30a breaker, Anderson connectors, wires and the inverter in the shop, so I just bought another charge controller then put them together.
This inverter sticks above the top rim of the crate, so stacking isn't possible, but the outlets are very accessible. The gray component is the MPPT Charge Controller and the MT50 is mounted to the top of the Lion battery. I didn't want to mount it to the battery either, but it was screwed to a piece of 3/4 pine, then only double backed taped on to the battery. Guess I should paint the piece of pine ePever gray, huh?? :{)
Right in the middle is an easy trip circuit breaker that shuts the entire system off, eliminating parasitic draw. I also mounted an Anderson connector to the lower side of the crate as seen in picture #3. The cigarette lighter "adapter" is seen just hanging over the top edge of the crate, and it plugs into the Anderson plug. I ran MP4 connectors for the solar charging out one of the side holes of the crate. During transport, I can just tuck them inside.
I am using a 100w single solar panel. I'm still playing/experimenting:{)
You might think that I used PENRO's example as a template, but I had not seen his post before doing my build. They turned out very similar. PENRO, they say that imitation is the greatest form of flattery.
I used some different components:
105 Ah Lion battery= $700 from CostCo on line.
ePever 20 a charge controller w/MP50 monitor = $115 - Amazon
1500w Pure Sine Wave Inverter = $160 Amazon
Assorted other connectors, breakers, wire etc =$25?
(replacement) crate - Amazon - $24
I used this system camping a few weeks ago. Ran the coffee maker, microwave (800w) and charged all phones, camp lights, and when I left the key on in my truck, charged 2- 12v batteries up enough to start the diesel, with a separate charger. I just charged the crate system with several different 100w panels. I was changing them out during the experimental phase. The Renogy suitcase 100w panel worked out the best, in case you were wondering:{)
Fun project and it is a good learning experience in the solar arena. Better deal than a similarly powered suitcase system, just NOT AS PRETTY!
DesertDave