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 negati.ve 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.



    RECENT POSTS YOU MIGHT LIKE
    • How to build a Simple Homemade Wood Burning Stove heater with Heat Exchanger for your Garage .No Electricity required and Inexpensive‚Ķ..
      This project goes into the build of a homemade wood burning heater with a heat exchanger for your garage . This heater is build from a recycled old propane tank . The other materials you need to build this heater are 55 gallon drum, fan blower, quarter inch steel plates , eighteen 2 inch steel pipes for the heat exchanger, welding unit, plasma cutter. Before cutting into the propane tank , make sure to clean the tank so that there is no residual gas left in it . Cut both ends of the tank using the plasma cutter. Now we cut a 30 inch length piece from the tank .This acts as a main body where the heat exchanger pipes are installed. The heat exchanger consists of 18 two inch pipes that run the length of the heater from front to back. Two quarter inch steel plates are welded at the ends of the propane tank . Before doing that we make 18 holes at both the ends of the steel plate. This is done to install the heat exchanger pipes across the length of the tank. With the help of an eighth inch hardboard, we make a template for cutting the 18 holes out of the steel end plates. The hardboard acts a guide for the plasma cutter to cut the holes. The pipes for the heat exchanger are cut 31 and half inches long. Half inch sticks out at both the ends of the heater. They are welded to the steel end plates at both ends. The opening for the door at the end of the heater for the wood intake has a dimension of 16 inch X 12 inch . A similar template is placed on the end plate and the opening is cut using the plasma cutter. A frame around the door is made using a three quarter inch by three sixteenths inch flat stock .This is used for the door opening and to give the door something to close up against. Hinges are welded near the door opening for attaching the door. The locking mechanism for the door to hold it shut is made using a flat stock and couple of bolts . The bolts are welded onto the flat stock and attached inside the heater just beside the door . The handle made of a 90 degree round stock is welded to couple of washers and the door is sandwiched in between. The end plates along with the door is welded onto the body of the heater at both the ends and a hole is made at the top of the propane tank body for installing the flue exhaust pipe. A small hole is cut near the door and a damper in the form of a simple sliding door is attached to the hole that will control the airflow into the heater. A section from old 55 gallon steel barrel is cut and welded onto the backside of the heater .An inexpensive fan blower is attached to this 55 gallon drum . This is installed to concentrate the air that is going through the heat exchanger pipes. The flue pipe is welded onto the top of the heater so that the harmful smoke and gases escape through the exhaust . A grate is placed into the heater through the door opening , wood pieces are introduced and the we start firing the heater. After few minutes , the fire will heat the heat exchanger pipes . The fan blower is turned on and the hot air is blown through the pipes into the garage . https://www.youtube.com/watch?v=-gwiT7Ps1F0
    • How to build a simple and effective Multi Purpose Waste oil Aluminum Scrapping Foundry / Forge out of Scrap Metal
      This project goes over the build of a convertible waste oil powered aluminum foundry / forge made out of recycled materials. Waste oil burning does get more than hot enough to melt down aluminum, which has a melting point of about 660.3 degree celsius. The materials you need for this project are old 10 gallon propane tank for the foundry, air compressor tank for the waste oil burner, blower from a car , three eighth inch hose and a brake line for feeding waste oil from a bucket, 12V marine battery for powering the blower. We take a car heater blower and house them inside an old tin can for the air intake. This is soldered to soup can and one and quarter inch schedule 80 pipe .This feeds air into the burner vessel. The fuel source which is the waste oil is drip fed from a five gallon jug with a brass gate valve. It is connected to the blower pipe through a three eighth inch hose and a metal brake line. The waste oil burner is from an old air compressor tank .It has a two inch cap on the top where we start the ignition and light the system. The pipe from the blower goes half an inch into the burner at an angle. This generates a cyclone vortex effect . We want to make sure that the oil and air are very well mixed together. In order to sustain combustion on something that's so difficult to ignite like waste oil, we have to have a source of heat so it can actually atomize, turn into a vapor where it will burn very easily and very effectively. The outlet from the burner is connected to the foundry propane tank through a three inch piece of axle welded with a rotating coupling piece. This can be rotated independently so that the foundry can be rotated to a forge mode with the help of a lever. We mark and cut the top of the propane tank that essentially forms the body of our foundry. Next, we are going to need to put a lining on the inside , probably about two and a quarter inches thick. This acts as an insulator. Here we use a 50% mix of plaster of paris and play sand. The propane tank is filled with the mix and the air compressor is submerged in the center to form a mould. We let the tank sit for 24 hours to cure before we remove the air compressor out of it. Next step is to create the hole into the side of tank that will be the outlet of our waste oil burner. The hole is cut at a height so that the the aluminum wont run down and back flow into the oil burner tank. We place a three inch axle through the hole that is welded to rotating coupling . This coupling attaches to the outlet of the oil burner. One the other side of the propane tank ,we add a small lever system with a latch to manually put the foundry into a forge mode. A one inch water pipe is connected to the tank .Inside of that one inch water pipe is this bit of one inch shaft with a hole drilled in to accept a three eighths inch bolt. A rebar with a latch mechanism is welded vertically to this pipe. The latch is pulled to pulled and the foundry is rotated into forge mode. The foundry sits on a cradle during the forge mode .The cradle is made out of two inch flat bar. The frame is constructed from one and a half inch by one and a half inch angle iron that I had laying around. To start the system , we use a little piece of rag cloth and poke it down into the inlet of the ignition port of the oil burner. We apply a little waste motor oil and start the ignition. Once the flame begins , we apply power to our blower motor by connecting it to the 12V battery. https://www.youtube.com/watch?v=l95fkSaaOEE
    • How to build a Homemade DIY Geothermal Heat Exchanger to Cool Your Garage
      This project goes over the build of a Geothermal heat pump that takes the hot air in your garage and cool it down by transferring that heat into water .The cold water is pulled out of the ground through a shallow hand dug well and send to a heat exchanger inside the garage . A fan attached to the heat exchanger blows out the cold air into the garage . The heat exchanger absorbs the existing heat inside the garage . The warmed up water is then removed through an exhaust pipe. Just a few feet down the earth is a consistent 55 degrees, summer or winter. Water at that depth is about the same temperature. To harness the cold water down below, we dig a shallow well. To do this we use a post auger and a 3 foot long well point that is attached to a 10 foot three quarter inch pipe using a drive coupling. We start by digging a hole using the post auger till the water table is reached and then start driving using the well point for additional two to three feet until it is submerged under the water table. A two to three foot trench is dug from where the well is installed to the garage . A One inch poly pipe is connected to the well pipe using a barbed coupling and is buried inside the two foot trench all the way to a well jet pump .The trench is dug down at least two feet until you hit some hard pan clay that is about where the temperatures begins being more constant. This keeps the pipe cool under the earth. The other end of the poly pipe coming out from the trench is connected a 1/2 HP Flotec Shallow well jet pump . The pump can be powered by a solar panel. The pump is kept outside the garage as it generates a lot of heat. If it is kept inside the garage, cooling effect from the water will be undone by the heat generated by the pump. The output of the pump is connected to a three quarter inch copper pipe inside the garage. It is then further connected to a water pressure tank with the help of a brass tee and a union. A relief valve is also attached to the tee to empty the water tank if the pressure gets too high. A water pressure tank is used prevent the pump from failure .It also acts as a buffer storage. The other end of the brass tee is connected to two pipes. One pipe goes outside the garage to a faucet and the other pipe is connected to a radiator that acts as a finned tube heat exchanger. The heat exchanger captures the hot air surrounding the garage and stores the heat into the finned coils within the radiator .The heat is transferred to the water flowing through them . An exhaust line from the radiator carries this hot water to outside the garage. Two flexible hose pipes connects the input of the heat exchanger to the water tank and output to an exhaust pipe. A box fan is placed in the front of the radiator to blow the cool air . The fan can be powered by Solar panels. Once the water starts running through the radiator , we start the fan https://www.youtube.com/watch?v=IRLLbmcnYjA https://www.youtube.com/watch?v=bCOeMIQLwgc