This article will provide a step-by-step guide to building a DIY portable solar power station. This project will allow you to power various devices and tools using solar energy, making it ideal for camping, off-grid living, or emergency situations.

 This power station features two 12V 50Ah TimeUSB Lithium Iron Phosphate (LiFePO4) batteries. Wired in parallel, these batteries provide a total capacity of 100Ah at 12V, offering approximately 1280 watt-hours of energy storage.

STEP 1 : The Materials Required

• 2 x 12V 50Ah LiFePO4 batteries (TimeUSB brand)

• 200W Solar Panel 

 

• 1 x 2000W Pure Sine Wave Inverter (Redodo brand)

• 1 x Solar Charge Controller compatible with LiFePO4 batteries

• 2 Gauge Wire (Red and Black)

• Wire Connectors (Ring Terminals, Spade Connectors)

• Wooden box with lid (size to accommodate the batteries and inverter)

• Plywood sheet for the lid

• Wooden planks for lid reinforcement

• Wood Glue

• Wood Screws

• Latches for the lid

• Drill

• Jigsaw

• Screwdriver

• Wire Stripper/Cutter

• Measuring Tape

• Pencil

STEP 2 : Determine Box Dimensions and Cut Wood

Measure the dimensions of your batteries and inverter to determine the necessary size for your wooden box.Cut the wooden planks to the appropriate lengths for the box sides and base, ensuring a snug fit for the components.

STEP 3 : Assemble the Box

 

Apply wood glue to the edges of the wooden planks.Assemble the box sides and base, securing them with wood screws.Ensure the corners are square and reinforce them with additional wood screws for extra strength.

Step 4: Prepare the Lid

Cut the plywood sheet to the size of the box opening.Cut wooden planks to reinforce the lid edges, creating a lip that will fit over the box opening.Apply wood glue to the edges of the plywood sheet and reinforcing planks.Assemble the lid by attaching the reinforcing planks to the plywood sheet with wood screws.

Step 5: Mount the Inverter and Create Ventilation

 

Determine the desired position for the inverter on the box, considering accessibility. The opening should be positioned on one of the side walls of the box.Mark the outline of the inverter on the box side.Use a jigsaw to cut out the marked area, creating an opening for the inverter faceplate.

Drill ventilation holes on the box side opposite the inverter. Size and placement should be adequate for airflow without compromising weather resistance.Secure the inverter to the box using wood screws, ensuring a snug fit.

Step 6: Install Battery Connections

 

Place the two LiFePO4 batteries inside the box, resting on the internal frame.Connect the negative terminals of both batteries using a piece of 2-gauge black wire and ring terminals.Similarly, connect the positive terminals of both batteries using 2-gauge red wire and ring terminals. This creates a 12V parallel connection.The batteries are connected in parallel to increase the overall capacity.

Step 7: Mount and Wire the LiFePO4 Compatible Solar Charge Controller

 

Determine the placement for the new LiFePO4 compatible solar charge controller on the underside of the lid, considering accessibility and wire routing.Mark the outline of the charge controller on the lid.Secure the charge controller to the lid using wood screws.

 

Connect the positive (red) wire from the battery bank to the positive terminal of the charge controller using an appropriate connector.Connect the negative (black) wire from the battery bank to the negative terminal of the charge controller.The inverter already has built-in overload protection, it will automatically shut off if it detects excessive power draw. Also, the solar charge controller has its own safety mechanisms to prevent overcharging the batteries from the solar panels.

Step 8: Connecting the Solar Panel and the DC Outlet

Here we use a The positive (+) and negative (-) wires from the solar panel are connected to the corresponding input terminals on the solar charge controller.Use an MC4 Y branch connector to combine the input from multiple panels.

Securely mount the DC outlet to the box using appropriate fasteners.Connect the DC power box to the battery bank using a suitable length of 2-gauge wire, ensuring proper polarity (red to positive, black to negative).These allow you to connect devices that run on 12V DC power directly, using appropriate connectors.

 

 

Step 9: Test and Final Touches

Observe the charge controller display to confirm that the batteries are charging correctly.Connect a device to the inverter and turn it on to verify that the system is supplying power.Connect devices to the DC power box, utilizing its various output options, like USB ports, a cigarette lighter plug, and 12V DC ports.

Image Credits : SSLFamilyDad