Solar Trailer: Part 6 - Toolbox and Electric Outlet Installation



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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: https://www.youtube.com/watch?v=juk39pA7E-E
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: https://www.youtube.com/watch?v=-ydKipDPgQE

Tools and Materials used in this project:
Xantrex C40 Solar Charge Controller: https://amzn.to/3F0pJ41
(I later upgraded the charge controller to an Outback Flexmax80. Find out why in a future video: https://amzn.to/3EYDoJ7 )
14S Lithium Battery (Leaf Cell Modules)
2200 Watt UPS (Recycled, Repurposed)
DC Circuit Breakers: https://amzn.to/3oeUkVL
Circuit Breaker DIN Box: https://amzn.to/2ZHjx0N
Solar Cable: https://amzn.to/3umPiHC
Replacement tool box gas lifts: https://amzn.to/3zMSVb7
DC Current/Power/Energy Multimeter Display: https://amzn.to/3ikkRwZ
Stainless Steel Cable Clips: https://amzn.to/3ATglwN
Anderson Disconnects: https://amzn.to/3oen7K1
Plug-In Electric Usage Monitor: https://amzn.to/3oeVZKZ
3/4" Pillow Block Bearings: https://amzn.to/3kOxan0
Weather-proof cord grip Cable Glands: https://amzn.to/3iinBej
DIN Rail Terminal Block Kit: https://amzn.to/3CZNBmr
Stainless Steel Zip Ties: https://amzn.to/3EYENiR
Outdoor Rated Metal 2-gang electric box: https://amzn.to/3oeqikV
Two-Gang Weather-proof outlet cover: https://amzn.to/3ojzWTu
Ryobi 18V Drill: https://amzn.to/3A3msxf
Step Drill Bits: https://amzn.to/3abVAAR

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"Shaving Mirror" Kevin MacLeod (incompetech.com)
Licensed under Creative Commons: By Attribution 3.0 License
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