My charging setup, the planning and build

[murankar]

The secret squirrel parts are ordered. I also found a illuminated push button switch and got 3 of them. 2 are for the PSUs and one for the secret squirrel project. Now to ask the wife if I can get the rest of the charger stuff. Excited for the new stuff to get here. This case is going to be an expensive case even though I went cheap. The biggest cost is the charger of course but all the bits needed to complete it are just as much even with out the secret squirrel stuff.

[murankar]

I finally got the Lexan for the deck lid, now I need a new sheet. I also got the PSUs wired in series finally along with 3 binding posts; 2 for 12v (1 from each psu) and 1 for 24V. I ended up at Microcenter (http://www.microcenter.com) and got a couple things, 2 80mm fans, grills and a white cold cathode light tube for the lid. I didn't plan on using a light but for the beans they were asking for the light I said sure why not.

The secret squirrel project if starting to come together. I am waiting for 2 more parts to come in to see if this is going to work. I hope it does because one of the items was upgraded for free from the retailer.

THe deck lid I have is a mess kind of. I did not thoroughly plan out the layout and went willy nilly. Due to this I have the binding posts in the wrong place and the exhaust fan needs to slid out few mm so it clear the PSUs. The power cables are going to need some working. One cable is based on 14 awg wire and the other is based on 18 awg wire. Needless to say one is beefier than the other and harder to work with. I will have to look and see if I have one that is closer in size to the smaller wire.

So as for now I am a lot closer to this thing being plug and play for the charger.

[murankar]

Its done I just finished ordering the rest of the stuff for the charging case. Yes the PL6 is in the order along with the last bits needed to finish the case. Now I really can't wait for this package. I should have this by the time I go back to work on friday night and should have this installed waiting for the season.

[murankar]

I am still waiting for the pl6 to show up. Here it is for now. Everything works and this little box is loud.

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[pvolcko]

Charger slash boombox. Cool!

[murankar]

I had to do it, I saw the deal on amazon and had to jump on it.

Now if my charger would just get here so I can finish it. Well I still need my switches too but thats minor.

[Graham Lawrie]

Looking good nearly finished:)

[murankar]

And can't wait. The rest should be here soon, I hope.

[murankar]

The rest of the Stuff came today. I am happier than.... Can't say the rest. The charger is real nice looking and the size is surprising. I was expecting something a little bigger . the case went through a redesign and I will post pics soon. Got a few more things to work out and a couple more holes to cut out. I think I will need another light for the case. I might look at LEDs instead, depends on what I can find. The led route will be more flexible due to size and twistiness of the strips. My new case can hold everything but it is more compact and easier to carry. I was also able to mount the pl6 right to the deck lid. This is something I wanted to anyways and with the design of the charger I was able to do it easier than I thought.

As for the PRC module charge boards, omg those things are huge. Well bigger than i thought they would be. Really nice and fuses out the wazoo.

Anyhow I will be posting pics soon.

[murankar]

Well the time has come, this box is fully function minus the glorified mp3 player. All that needs is the holes cut for the speakers. Those will be added in a few days. I am not looking forward to cutting out the holes. Imy dremel is not up to par for the task so the copeing saw is going to be used. The dremel can handle the sanding of the holes to clean them up.

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[pvolcko]

Saw could work, but personally I'd drill out a bunch of holes around the inside perimeter of the traced out circle then use the dremel to cut out the connecive parts. They make router type bits for them that should do nicely. Coping saw can work too. Just another option.

[murankar]

I got one done already. Need to finish the other. I might look at a drum sander for my drill. That would make quicker work of it. I wish I had a hole saw for my drill. That would make a nice hole with some minor touch ups.

I have 2 different bits for grinding/cutting. Both work just my dremel is to weak for the task. Its something like the 100 series. Not ment for hard cutting and grinding.

[pvolcko]

ah. Cool. Can't wait to see the finished product. And hear it. Need video on this one.

[murankar]

No problem. The sound won't sound great because if the mic on the phone.

[murankar]

Its all together with everything I need for the field or home charging. One of the blue switches has a bad light and needs replaced, thankfully I have one extra switch in the case I can use. I can assure you the switch is on. Bad thing is the switches have the wires soldered to the prongs. I switched all the EC3 connectors on my packs to the correct plastic housing but still need to fix the esc. The music you here is coming from the case and not me adding it in later.

I had a last minute theme change with the case being black and green. I decided to continue the theme with the lighting. Since I now have Pulse Ultras I thought I would continue with the color. Now I just need to finish the template of the Pulse logo. Not sure where to put the logo but it should help add to the uniqueness of the case or tool box which ever you like.

A good chunk of this case came from Progressive RC. My list includes PL6, charger board, EC3 connectors for the batteries and ESC, PC link for the PL6 and the 10AWG wire read and black. Everything else I got locally or through Amazon.

One last thing I added is padding for a metal tool box. Its a rubberized foam pad that I placed on the bottom of the box and I cut a piece to cover the PSUs. I did this just in case my amp touches the PSU. It shouldn't, I am being overly cautious on this.

https://youtu.be/2rski6Se3Ag

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[Superbad]

Holly crap it plays music

[Lee]

Looks pimp mate

[murankar]

Thanks Lee. Yeah the music will make for a fun time at the field. The club members have generators so now we can play music while flying without the need of a car stereo.

My first case would have worked fine but it was a bit bulky to carry. So in came the tool box. The color theme was unplanned and worked out in the end. The only purpose of the lights is the cool factor and that's it. They don't produce enough usable light to make it worth it. At least with where I have them. LEDs in the lid would make great usable light.

[Graham Lawrie]

Very nice Matthias:) love the music touch:)

[murankar]

Thank you. It was a "let's see if it works" idea. I didn't think it would.

I finished up the connector switch out on the ESC and switched my very old Gens ace packs also. I had to reuse 2 female metal fittings to complete the third pack. All I did was dremel the plastic and unsoldered the old wires. Any ways its all done and ready for the first charge cycle.