Solar Trailer: Part 6 - Toolbox and Electric Outlet Installation

Today, we install the battery and electronics enclosure, wire up an electric outlet, and test it!
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Part of the idea behind this project was to do it on a very small budget! I needed some sort of weatherproof box to house the battery and electronics. I found a truck tool box on Craigslist for $50. I replaced the lid gas lifts and replaced the key/lock on it. That gives me a secure and weatherproof container for my components.

I'll want an electric outlet on the OUTSIDE of the box, so I wire up a 20A/120V outlet in an exterior grade cover. The UPS which I am using as my inverter already has outlets and AC circuit-breakers built-in, so I essentially just need to wire up an extension cord from the UPS to the outlet.

Time Stamps:
0:05 Intro
0:43 Installing tool box to frame of trailer
2:01 Strain-Relief and weatherproofing for solar wires
3:21 Install box for outlet
5:00 Wiring the cord
7:05 Wiring the outlet
8:00 Testing the outlet
8:51 Next Time

This project is a bit of an experiment in building a portable, off-grid solar system using mostly what I already have. The Charge Controller is one that I've already had for years. The battery is made from 7 Nissan Leaf Cell modules. See the video on building the battery at:
The inverter is a repurposed Uninterruptable Power Supply (UPS) which ran on 48V and would have originally been used in a computer server room. I'm just using the inverter portion of this unit, but it could also be used as a battery charger if I connected it to wall AC power. I used this same unit to power my house during a blackout from my motorcycle. Learn more about that at:

Tools and Materials used in this project:
Xantrex C40 Solar Charge Controller:
(I later upgraded the charge controller to an Outback Flexmax80. Find out why in a future video: )
14S Lithium Battery (Leaf Cell Modules)
2200 Watt UPS (Recycled, Repurposed)
DC Circuit Breakers:
Circuit Breaker DIN Box:
Solar Cable:
Replacement tool box gas lifts:
DC Current/Power/Energy Multimeter Display:
Stainless Steel Cable Clips:
Anderson Disconnects:
Plug-In Electric Usage Monitor:
3/4" Pillow Block Bearings:
Weather-proof cord grip Cable Glands:
DIN Rail Terminal Block Kit:
Stainless Steel Zip Ties:
Outdoor Rated Metal 2-gang electric box:
Two-Gang Weather-proof outlet cover:
Ryobi 18V Drill:
Step Drill Bits:

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Music by:
"Shaving Mirror" Kevin MacLeod (
Licensed under Creative Commons: By Attribution 3.0 License

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