DIY LiFePo4 Battery Enclosures - Van Build Series

Kieron Moorman
Kieron Moorman

Hi, excellent video. Do you happen to know the final external dimensions of your boxes? I would like to make one for my van, and I have a space that has a max size I can fit in. Thanks.

Vor 10 Monate
Wandering Zythophile
Wandering Zythophile

10 3/4" H, 10 1/2" W, 16 1/2" L. Made with 3/4" ply. It's a bit oversized, there's open spaces inside that are larger than necessary. Part of the size is due to the end pieces needing to be wide enough to accomodate the threaded bars being spaced away from the cells enough that they don't touch. I've been pondering redoing these boxes, been keeping eyes open for suitable containers on the market, but the ones I find are either too small, too big, too flimsy. Frankly the best DIY solution I've seen online is this company's offering, but it's kinda pricy; https://www.sunfunkits.com/product/1/sfk-battery-kit-v1-280ah-4s-12v-lifepo4

Vor 10 Monate
RV10flyer
RV10flyer

the aluminum case is connected to the postive terminal through leaked electrolyte from manufacturing. Some cells are worse than others. Usually around 10-30mA of current flows if you provide a short from the cell case to your negative terminal. That's about the same amount of current to power your BMS. It will run your battery down over time. I used 1" cargo straps. I use high temperature polyamide tape between my cells and covering cell terminals/busbars. I use quarter inch ceramic fiber cloth around the whole battery to prevent wood from catching on fire in case of a cell malfunction.

Vor 4 Monate
Alexander F
Alexander F

Thanks for sharing! Thats first proper video i found of good DIY box for our cells. Ive made few boxes for 100Ah cells but never liked end result. Just came into possession of 8 of these exact same cells and will copy/reverse your boxes!

Vor 8 Monate
Michael Doherty
Michael Doherty

@Wandering Zythophile I used an acrylic sheet across the top of the battery and attached the BMS to it . Its totally isolated from the battery and has air space all around it so it really can't get hot.

Vor 8 Monate
Wandering Zythophile
Wandering Zythophile

The boxes are really simple, there's not much to them. I think the one thing I did that was unusual was to mount the BMS to the separate piece of wood and then mount that up to the wall. All the other videos on DIY enclosures, the BMS seems to always be held down by tape, meh! One option would be to go that same route with the BMS, but to attach it to the inside of the lid rather than on the inside of one end. Obviously you'd have to build the box that much taller, and add some sort of material or shield in, to make sure there's not the possibility of contact between the BMS and the cell terminals just below, should you hit a bump or something. Using the proper flexible welding cable is key too.

Vor 8 Monate
Michael Doherty
Michael Doherty

That is a really nice looking DIY box. Couple of comments I gleaned from my own experience. I'd like to see a non-conductive layer on top of the battery for safety. Clear acrylic sheets work well. Not sure why you used heavy 3/4" plywood for the box. 1/2" or even 15/32" is very strong and lighter. The Blue Sea terminals are nice, but I would have set them with the mounting screws on the outside of the lid. Covers the drilled holes and looks much nicer. The aluminum flat bar between the threaded rods is doing nothing but adding weight and not strength. If you run a screw through both sides of the box into the compression plates on the ends of the battery it can't move in inside the box. That works well if you are using it in a RV where vibration can make the battery assembly walk inside the box. I am in the process of building a similar box for a 412ah battery. Insulating it with foil faced 1/2" polyisocyanurate sheeting to keep the battery warmer in cold weather and cooler in the summer heat. You did nice work. The hinged lid was something I like a lot. I was going to just screw my lid down, but I may use hinges now.

Vor 10 Monate
Michael Doherty
Michael Doherty

@Wandering Zythophile You'll have to have a pint of guinness and chill. I have to get some work done outside before the rain hits and the clouds are really dark to the west.

Vor 8 Monate
Wandering Zythophile
Wandering Zythophile

Oh zero hurry :) Thanks!

Vor 8 Monate
Michael Doherty
Michael Doherty

@Wandering Zythophile Will do. I'll try to get it done today.

Vor 8 Monate
Wandering Zythophile
Wandering Zythophile

@Michael Doherty Yeah, if you wouldn't mind sending some pics, I'd love to see them. wanderingzythophile at gmail is the addy. Thank you!

Vor 8 Monate
Michael Doherty
Michael Doherty

@Wandering Zythophile I've got a few photos but I really didn't document it in a orderly way. I just don't have the skills (but mainly the patience) to video and edit like you guys do. I originally built 2 -206ah 4s batteries and paralleled them inside the ione box to the external terminals. I put a 200a JBD BMS on each one. It was overkill but that's what I wanted. It worked great but I couldn't get the 2 batteries to sync properly. When fully charged, one was 206 ah and one was 176ah. I still don't know how that happened because I top balanced all 8 cells together. I got frustrated with how the 2 blue tooth modules seemed to fight one another and the data looked strange, so last week, after camping with it for 2 weeks, I broke it down and paired the cells 8 cells into a single 4s2p pack, top balanced again, and reassembled it with one 200a JBD bms. Now it is perfect. It charges to 412ah and my Victron smart shunt and the one JBD BMS are totally in agreement. I couldn't be happier. I use a 2000W Renogy inverter to run my microwave for cooking, and a Renogy 60a dc-dc charger from my Ram so I can run my refrigerator on AC when on the road which is safer than propane. It all works really great so I am really happy. I could drop you some still pics and dimensions, but that is about the extent of what I have.

Vor 8 Monate
MarkTheUnitedStatesCitezen In Jesus Name Acts 2:38
MarkTheUnitedStatesCitezen In Jesus Name Acts 2:38

Great ~ Job with the Battery Compression

Vor 5 Monate
Lawrence Davidson
Lawrence Davidson

Nice job! Well done! Music was too blaring loud tho. Greetings from Jamaica.

Vor 4 Monate
Wandering Zythophile
Wandering Zythophile

Still working on editing skills. Thank you for the feedback!

Vor 4 Monate
Fibra
Fibra

Hey mate, do you have a link for those raised therminals?

Vor 3 Monate
Fibra
Fibra

@Wandering Zythophile Thank you!

Vor 3 Monate
Wandering Zythophile
Wandering Zythophile

Here you go: https://www.amazon.com/gp/product/B08L1N2SJZ/

Vor 3 Monate
MarkTheUnitedStatesCitezen In Jesus Name Acts 2:38
MarkTheUnitedStatesCitezen In Jesus Name Acts 2:38

Great - Job

Vor 5 Monate
Enjimeer JIM
Enjimeer JIM

could do without the sound effects..............................

Vor 2 Monate

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