How to build a Portable 420 watt Solar Power Generator . Very Detailed Video Instructions,perfect for beginners

    This project goes over the build of a 240W Solar Generator made out of an ammo box.The box is large enough to hold a 240 watt deep cycle battery.

    There are some basic tools that you are going to need to build this generator.Number one tool, you’re going to need a drill. If you don’t have a drill, you can find one at Home Depot, you don’t have to spend a lot of money.Next thing you’re going to need is a screwdriver. Next, you’re going to need wire cutter, a wire cutting and stripping tool. And it’s also got a crimper on there.

    To drill the holes in the metal ammo box,you need a step up drill bit which can drill different sized holes, using all the same drill bit.You will need a pair of pliers which might be handy when you are cutting and manipulating wires and then basic wire cutters which also we have on the pliers.

    The next thing that you’re going to need is the heart of the generator, which would be the battery. Now this is a rayovac deep cycle battery.I recommend that you use a V max deep cycle battery.

    The next thing you’re going to need is a USB port. This is a two port device, it’s got a one amp outlet and a 2.1 amp outlet.You’re also going to need a 12 volt outlet.

    Faceplate,blade fuse holder,terminal connectors,switch,self tapping screws,14 gauge 17 amp black and red wires.

    We use a 3 prong switch,one of them gold in color which is the negative terminal and the other two positive.Purpose of the switch is to control your USB outlet. And it’s what turns the USB outlet on and off.

    The positive terminal on the USB outlet is first going to run to the positive terminal on the switch.Now the purpose of this switch is to break the electrical current when you turn it off. So positive terminal goes to positive terminal, then the second positive terminal on that switch goes to the positive terminal on the battery. So you’ve got a flow of electricity going from positive through this switch to the positive terminal on the USB port.

    The negative terminal on the switch goes to the negative terminal on the battery. The only purpose of that terminal is to control the LED light on the switch, it needs the both positive and negative electrical currents in order to turn that light on.

    Similarly for the 12V port,positive connector going to positive terminal going to the positive terminal on the battery.

    Lets start the build.
    Start with drilling holes for the ports using the faceplate.Get your marker and simply trace the inside from both the top and the bottom.So that’s where your holes are gonna go. Now we want to find the exact centers that when we’re drilling.

    Insert the 12V and the USB outlet into the holes which we have just drilled. Now these ports have a little ring that screws on the back. This is what holds it in place.

    Next thing we’re going to install is the power switch and SAE Solar Power Socket and the voltmeter.

    To begin wiring our tabs batteries, you’re going to need a few things. Number one, you’re going to need a battery. Number two, you’re going to need your quick disconnects. You’re going to need your squeeze connector connector,your wire cutters and stripping tool and you’re going to need black and red wires.

    Place the vmax battery into the ammo box.So we’ve got everything in place, we have our ports in place, we have our battery in place, we’ve got our switch in place, and our volt meter. We’re gonna start by wiring the USB port.

    The positive connection of the USB port is connected to the positive of the switch which is further connected to the positive of the battery.The negative connection of the USB is connected to the negative of the battery.

    This switch will break the flow of electricity on the positive side and that’s what’s going to turn our USB port on and off.

    Using squeeze connectors,USB port negative terminal is now connected to the same negative terminal as the 12 volt port.Connect the positive terminal from the switch to the positive wire which is coming from the 12 volt port and continue that positive flow from the switch to the positive terminal on the battery .

    So we now have our USB port and our 12 volt outlet connected to the battery through the power switch. We’ve got the negative terminal of the USB port, going to the negative terminal on the battery, we have the positive terminal of the USB port.Then we’ve got a positive going from the switch to the positive on the battery all through quick disconnects.

    The negative terminal on the battery going to the negative terminal on the switch simply allows the switch LED light to turn on without this negative current flow of electricity. This the LED light has no power.So we want to give that light power by connecting to the terminal on the battery.

    The negative of the Voltmter is directly connected to the battery and using insulated clamps,we connect positive wire that’s already running to the switch for the USB port.Now we want to connect to the positive wire leading to the positive terminal on the switch so that the volt meter will turn on and off with the switch button.

    Next, we’re going to cover the SAE port. We want to be able to have the battery charged when we plug this into a charger.Using the squeeze connector we connect the positive to the positive terminal of the battery.And then same thing for the negative, you would take your squeeze connector and connect to the negative.

    Lastly,A 15amp fuse is used to protect the generator from overloading. If you connect at current that is too high for their internal wiring to handle, the fuse will break and it will stop all electrical current from flowing.So if anything goes wrong in any of this wiring, it has to get past the fuse before it reaches the battery. So if there’s anything that’s that’s overheating, or overloading this fuse is gonna blow and it’s gonna protect your battery from being damaged .

    Next step is connecting a solar panel to your generator .We connect the panel to the charge controller and then from the charge controller to your ammo generator. A charge controller prevents the battery from overcharging. You don’t want to get over 15 volts.

    Here we use Renogy 30 watt solar panel, this panel comes by default, with an SAE connector on the back. This is the same kind of connector that plugs into your generator.

    Connect the wires coming out of the Solar Panel into the charge controller.Next is connecting the SAE cord from the generator
    to the charge controller.

    So you just put the panel on the charge controller, the charge controller into the generator, and you’re done.

    If you want the whole system to be portable, say you want to be able to take your solar panel and your generator camping, you want to keep things as simple as possible, you could actually mount the charge controller directly onto the back of your panel.

    • How to build your own DIY off grid / grid down Solar Power Back up system from scratch
      This project goes over the build of a Solar Power Grid Down Backup System to generate your own alternative power.A great way to utilize renewable energy as a backup source of power. Whatever may be the reason , may be to offset electricity bills or for self reliance to provide when the grid goes down, a solar backup system is simply a great way to provide alternative power to maintain a lifestyle of reasonable convenience. If the grid should go down, I can have a freezer, power lighting, pump water, maintain communications, use tools, and charge every little device I have from flashlights to kindles. This Off grid Solar Power System is composed of 5 components. Solar panels to generate the power, a charge controller to charge the batteries, the batteries to store the energy, the inverter to provide AC to the household items you wish to power. Also you need a Kilowatt meter. The kilowatt meter measures two things you have to know how much energy your devices draw at any given moment, and how much power they consume over time. Here we use 100 watt monocrystalline panels, a 40 amp MPPT charge controller, a 1000 watt pure sine wave inverter and to store the energy, 446 volt golf cart batteries totaling 470 amp hours. First you need to size your system by figuring out how many devices you are going to want to run at the same time. This will determine the size of your inverter, the inverters function is to take DC power from the batteries and converted to AC power for use with household appliances. If I have 1000 watt inverter, this means I can run up to 1000 watts worth of devices at the same time. Once you have evaluated every device that you feel that you are going to need, should the grid go down, you are gonna have a good idea of how much power you need to generate each day. The battery bank consists of four, six volt, Duracell SLIGC 125, golf cart batteries connected in series. Golf cart batteries are designed to deliver a lower amount of power over a longer period of time and then recharge quickly. When picking a spot to locate your panels, you have to consider that the sun will be lower towards the horizon in the winter, and closer to directly overhead in the summer. Building a system that actually tracks the sun would be best as the panels are always pointed directly at the sun. Also mount your panels as close as possible to the batteries. This is because the longer your wire run, the more energy is wasted due to resistance. You also need to select the proper gauge wire to transmit the power from the solar panels to the batteries. Between the panels and the batteries is the charge controller ,it controls the charge of the batteries and make sure that the batteries get the proper voltage that they need and that they don't get overcharged. Here we use an MPPT Solar Charge controller. If your solar panels are wired in series and connected to an MPPT charge controller, the voltage adds up ,thus giving us enough voltage to charge the batteries. An MPPT charge controller can charge your batteries nearly the entire time The sun is out. If your panels are far away and you want to save money and wiring, then the MPPT charge controller is way more efficient than PWM. The first step in making your solar system safe is making sure that there's an automatic and a manual way to disconnect power in each segment of the system. Starting right here at the battery box we have a 300 amp manual switch to kill the power from the batteries to the inverter as well as a 200 amp fuse that will blow automatically. Another component to the safety is the grounding. Grounding your system is quite easy to do. So get an eight foot grounding rod and drive it into the ground. Then pick up some copper grounding wire, some lugs and connect the frames have all the panels in any metal components in the system including the charge controller and the inverter.
    • DIY Video : How to build a 100W Super Bright LED Flashlight using a PVC pipe and Dead Laptop Battery
      This video shows the build of a super bright 100W LED flashlight in PVC pipe housing.Main parts bought from ebay. The battery of this flashlight came from 18650 lithium cells removed from dead laptop batteries.The other materials required for this build are 100W LED COB chip,100W LED Reflector, lens, lens bracket kit,DC to DC boost converter 250W,DC to DC step down (buck) converter.Some parts bought at local electronics or hardware store.Rest all stuff had lying around.The other video shows the build of the 22V 6Ah battery pack from dead laptop batteries.

      Watch the DIY Homemade 100W LED Flashlight using PVC and Laptop Battery Build

    • DIY Video : How to build a simple Off Grid Refrigerator using a 5 gallon bucket . No Ice Needed !!
      This project goes over the build an off grid survival fridge using a five gallon bucket . It has a peltier cooling module on the top. So no need of refrigerant or ice cubes. The materials you need to build are as follows. A 12V 12A Thermoelectric Peltier Refrigeration Cooling System unit from Amazon, a 5 gallon bucket , 4 gallon Styrofoam liner from Home depot. This refrigerator works by the principle of peltier effect. The Peltier effect shows that a temperature differential is created when a DC current is applied across two different materials .The peltier unit is made of using two thin ceramic wafers with a series of n and p semiconductor materials sandwiched between them. The ceramic wafers add rigidity and provide the necessary electrical insulation for the module. The n type semiconductors have excess electrons, while the p type have a deficit of electrons with one n and one p making up the junction couple that creates the thermoelectric effect. When a DC current is applied to the circuit, the thermoelectric module can work as a cooler or heater depending on the direction of the current. A thermoelectric cooler or tech transfers heat from one side of the device to the opposite side against the temperature gradient creating a cooling effect. We use heat sinks and CPU fans on the peltier chips to radiate and lower the heat generated on the hotter side and move the cooler air into the bucket from the cold side. The peltier setup in this build uses two 12V 92mm fans on the hotter side glued to a large 200m X 100mm Aluminum heat sinks, two 12v 5.8amps peltier chips are glued under two 40mm heat sinks using thermal paste. 2 40mm fans are also attached to the heat sink. The Styrofoam liner is inserted in to the five gallon bucket . Two small rectangular cuts are made on the lid of the liner so that the heat sinks fits inside there and gets good airflow around the edges. We cut a rectangle on the top lid of the bucket to allow the peltier module to sit in. Small vent holes are drilled on the sides of the lid using a standard quarter inch drill bit so that no hot air gets caught between the bucket lid and the Styrofoam lid. Cut a small notch in the bucket using tin snips so the wires from the peltier units will come out without getting pinched under the lid. You can hook this unit to 100 watt solar panels straight , 12 volt deep cycle battery, 12 volt transformer to the wall, or you can use your car CIG lighter. This unit can drop the temperature inside the bucket from 81 to 47 degree Fahrenheit in minutes.