Diy battery boxes

[finite]

Just a quick battery box question..ive never seen one, ive never assembled one.
I have this aluminum case that was previously used to ship wine bottles in(from tiger woods FL house, the one he lost in the divorce. Was a really nice house.) It fits my bank nicely with room for insulation and the BMS. For you more experienced folks would you forsee any shortcomings of using this?

 

[sunshine_eggo]

My only concerns would be 1) weight, but that looks pretty thin and 2) stiffness - you don't want it flexing excessively when moving and 3) clamping - can you still properly clamp the cells inside the case?

 

[chrisski]

How will you secure the batteries so the top does not short out?

As in the battery box gets turned upside down.

 

[finite]

My only concerns would be 1) weight, but that looks pretty thin and 2) stiffness - you don't want it flexing excessively when moving and 3) clamping - can you still properly clamp the cells inside the case?

The box itself is only a lb or 2 and it doesnt feel like anything is flexing when its lifted with the batteries inside. Theres still room for a plywood clamping device inside, probably will be able to fit the inverter in there as well.

How will you secure the batteries so the top does not short out?

As in the battery box gets turned upside down.

I will line the top of the cover with some plastic probably from an old rubbermaid bin or make a cover i can place over the top of the bank.

 

[finite]

Potential bolts fro a plywood clamp, or i may use 3/8" threaded rod(have it laying everywhere.)

 

[42OhmsPA]

Don't forget insulators between the cells.

 

[Brucey]

And the bottom.

 

[finite]

Basic layout, have a piece of plastic lining the bottom, insulaters at the ends and between each cell, still waiting on bms to arrive. inverter was a gift from an old employer if you were curious about the selection lol

 

[sunshine_eggo]

I was on board as a battery box. Sticking a heat source in there means you need ventilation. If that's a modified sine wave inverter (given the price, it has to be), I would discard it.

You're powering a Yugo with jet fuel.

 

[finite]

I was on board as a battery box. Sticking a heat source in there means you need ventilation. If that's a modified sine wave inverter (given the price, it has to be), I would discard it.

You're powering a Yugo with jet fuel.

You are correct i will be ventilating it, i have personally struggled with where to mount this inverter its intended purpose i believe was for under a work van seat. The unit itself has fans on so long as i can cut a hole in the aluminium cover and keep the rain from filling it up it "should" be OK maybe even beneficial in the winter to keep the cells warm if hole is covered. It will probably get changed at somepoint. Hell ive never even tested this inverter, it could be DOA.personal learning experience i suppose, and ill prolly buy a legit case with next battery.

 

[finite]

Well with the sun fast setting i managed to stuff everything the box for a quick test run.
Cant even lie its kinda janky, gotta fab up a legit buss bar for these neg and pos posts cut some holes for wires to pass throug, local auto parts stores dont have crap for fuse blocks, had 1 terminal mounted block but it was missing parts. The search is on.

 

[finite]

Well i was finally able to get that bank of batteries charged and noticed the bms allowed cell #2 to reach 3.7+v with a high volt cut off set at 3.6, so the daly is getting returned and am in the market for a new bms, which is ok since ive got some time doing a top balance after i had tested the system for function. I will be expanding this battery bank, ideally to a 48v system for my house, is it possible to use Bms on banks smaller than there inteded fo ex ample a 16s bms but only using 4 of the cells?

 

[finite]

Ordered a 4s-8s JK BMS with 2amp balance, not exactly what i was hoping for but it will hold me over until im at 12s and will be able to use it else where once this bank gets large. Since beginning this top balance process i have developed a new respect for just how much it takes to fill up these 304ah cells. I got impatient waiting on a 4s1500mah drone battery, this is another level...like 100floors up.
ETA-
Also got the box in its final form as far being operational without having to open and close it. The connections from the SCC are passed through some gromets and out through a plastic hooded cover plate, as well as one for the little bluetooth module(the range is trash stuffed in a metal box) and cut in a receptacle wired up with a piece of 12/2RX that i threw a cord cap on. I didnt use a box but a plastic old work low voltage ring and a couple shims due to the thuckness or lack therof of the aluminum cover. Of course with a code compliant in use cover. Ive been keeping the box covered during the day just to mitgate any excess heat but there hasnt been much of a load so not a whole lot of heat going on.