Built a ham radio battery case

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Built a ham radio battery case

Postby Jack Crow » 2017-Jun-Sun-19-Jun

Hi all,
One of the ham radio buds had an idea. It involved putting a gell cell battery inside a plastic ammo box and using one of my meter panels for the interface.

Since then my boss and one of the guys at the Chesapeake VA club built similar items.

Ive had this 12v 4 amp gell cell kicking around for years.

Did not want to spend the additional money on a 7 amp gell cell.
The design is flexible.
Some new parts and the case can hold the bigger cell.

The battery as I was using it was clunky and there was always the chance of a stray tool shorting the terminals.

Time to get started.

Went to Harbor Freight Saturday and they had this special on a plastic ammo can.

One of them is a panel that holds a small dc volt meter module, a pair of Anderson power pole connectors, and an on /off switch. This fits in a two inch hole.
5-7-2017 007.JPG

While I was at HF they had a cheap hole saw kit, picked up that as well.

Drilled the hole and mounted the meter panel.

Then I got to noticing how the battery would slide around inside the ammo box.
Had to make two 'cups' that would wedge the battery in the long direction.
These were complicated due to the fact the case was injection molded, so there is a taper in the case to free it from the mold.
Had to make my cups thinner at the bottom than at the top on all four sides. Took some effort duplicate the taper.

With the cups bolted to the bottom of the ammo box, then a battery bracket holds the gell cell in place to keep it from hitting the back of the meter module if bounced.

The first photo is the top view. Too bad the flash wiped out the LED's.
6-25-2017 005.JPG

Second is the inside of the meter panel.
6-25-2017 006.JPG

Third photo shows the 'cups' that can now hold stuff plus the battery hold down bracket.
6-25-2017 008.JPG


I think it's slick.

That's my excuse and Im sticking too it.
Jack Crow
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Built a ham radio battery case

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Re: Built a ham radio battery case

Postby Mooselake » 2017-Jun-Mon-09-Jun

Nice! Need to get going on the DC wiring in the Hamper (ham radio camper) now that FD17 is over.

Did you participate in field day? Ours was cold and wet, the bands were poor, but the food and turnout was good. One visitor had just upgraded to extra that morning but couldn't stay and operate. We were right next to an old mineshaft, one station used it for a very high end of a sloper

Kirk
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Re: Built a ham radio battery case

Postby Jack Crow » 2017-Jun-Mon-16-Jun

K
Thanks for the kind words about the project.

As for the weekends other event, I don't take part in field day.

After two years in Iraq and Kuwait, that last thing I ever want to do is spend time in a tent.
Call it a mental quirk. Let the younger kids do that. Got nothing to prove any more.

Don't look forward to being bug food either.

Be well there.
Jack Crow
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Jack Crow
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