Battery box upgrade for 10.6

VAPoorBoy · 04-04-2021, 02:02 PM

Finally finished my battery box upgrade. Built it to sit in the stock location of the battery box holder. It can hold two group 24 batteries. Currently just a single battery installed. Have a small 10amp waterproof charge controller inside just for the lid mounted 10w solar panel. The controller also powers a couple of led lights just in case I need to check anything in the box at night. All connections have waterproof fuses installed. The renogy charge controller is located in the kitchen bay to keep it protected from the elements. Circuit breakers installed there as well.

marty1954 · 04-04-2021, 09:43 PM

what are the dimensions between the wall and the LP tanks?

VAPoorBoy · 04-05-2021, 04:48 AM

Quote:

Originally Posted by marty1954

what are the dimensions between the wall and the LP tanks?

Between the front wall and the LP tank is 1.5".

marty1954 · 04-05-2021, 08:14 AM

hi, my bad, between the front wall of the camper and the tanks (I dont have my NoBo yet).

Tundra 2014 · 04-05-2021, 04:39 PM

Nice set-up.

Larry-NC · 04-05-2021, 05:09 PM

Nice work. If you haven't done it, you might consider a few small drain holes in the bottom of the box. Seems like there's always condensation...

VAPoorBoy · 04-05-2021, 05:14 PM

Quote:

Originally Posted by marty1954

hi, my bad, between the front wall of the camper and the tanks (I dont have my NoBo yet).

Gotcha, no problem. It's 9" at the closest point.

VAPoorBoy · 04-05-2021, 05:15 PM

Quote:

Originally Posted by Tundra 2014

Nice set-up.

Thank you.

VAPoorBoy · 04-05-2021, 05:18 PM

Quote:

Originally Posted by Larry-NC

Nice work. If you haven't done it, you might consider a few small drain holes in the bottom of the box. Seems like there's always condensation...

I definitely added drain holes spaced evenly across the bottom. The dealer installed plastic box had about 2.5" of water when I removed it.

VAPoorBoy · 04-05-2021, 05:27 PM

Couple of pictures of how the wiring goes in from the bottom.

jimmoore13 · 04-05-2021, 06:10 PM

Sweet!

VAPoorBoy · 04-05-2021, 07:26 PM

Quote:

Originally Posted by jimmoore13

Sweet!

Thank you.

marty1954 · 04-07-2021, 10:07 PM

nice set up... what are the dimensions of the box and where did you get one that would fit between the camper wall and the LP tank?

VAPoorBoy · 04-08-2021, 05:49 AM

Quote:

Originally Posted by marty1954

nice set up... what are the dimensions of the box and where did you get one that would fit between the camper wall and the LP tank?

I looked all over the net and couldn't find anything that would fit in the stock location. I ended up making the box myself. I'll need to get the measurements off of my cardboard template I made and post them once I get home. I used the template to cut the aluminum sheet. A single 2'x4' covers the main material. Aluminum angle and flat was used as well. The first picture in the post shows the cut sections along with the bends of the main body after using my metal brake. I used my plasma cutter to get the cuts as clean as possible before sanding any rough edges.

DES-1 · 04-08-2021, 03:11 PM

Quote:

Originally Posted by VAPoorBoy

I looked all over the net and couldn't find anything that would fit in the stock location.

NOBO's don't have much room to work with, by the time dual tanks and batteries are added it's pretty cramped.

A locking box must have been a priority for you. There are plenty of single and dual boxes available but are plastic. My box holds dual golf cart batteries...but there was no room in the box for a battery shunt or a master switch, so I used the smallest boxes I could find for those and mounted to the side of the tongue.

VAPoorBoy · 04-08-2021, 05:28 PM

Quote:

Originally Posted by DES-1

NOBO's don't have much room to work with, by the time dual tanks and batteries are added it's pretty cramped.

A locking box must have been a priority for you. There are plenty of single and dual boxes available but are plastic. My box holds dual golf cart batteries...but there was no room in the box for a battery shunt or a master switch, so I used the smallest boxes I could find for those and mounted to the side of the tongue.

Yes, I wanted to be able to lock everything and make it a bit more difficult for someone to just grab and go.

VAPoorBoy · 04-08-2021, 05:40 PM

Quote:

Originally Posted by VAPoorBoy

I looked all over the net and couldn't find anything that would fit in the stock location. I ended up making the box myself. I'll need to get the measurements off of my cardboard template I made and post them once I get home. I used the template to cut the aluminum sheet. A single 2'x4' covers the main material. Aluminum angle and flat was used as well. The first picture in the post shows the cut sections along with the bends of the main body after using my metal brake. I used my plasma cutter to get the cuts as clean as possible before sanding any rough edges.

Marty, here's a couple more pictures that tie into the first picture of the cut and bent material. The box as 24" wide. The other dimensions for making the bends of the main body are based on the sides which were the basis of the project. Starting from the front of the sides, then going down and then up the back are as follows. 8", 4", 4", 8", 8", 4.25", 1". The lid is 8"×24" and has some weather stripping. Cardboard is your friend when making odd pieces.

Also, almost forgot. Due to the nature of bending with a manual brake, the front and the little 1" at the back ended up a little bit long. This actually worked in my favor as it let me add a lip to the front and back for the lid.

kennedy101 · 07-05-2021, 09:44 PM

@VAPoorBoy, that's some very nice fabrication and electrical work. Well done sir. Thank you for sharing the dimensions for those of us that might try building the same. I'm curious, did you TIG weld and if so what's the welder you used? Makes me want to get my air compressor setup to use the plasma!

VAPoorBoy · 07-06-2021, 07:29 AM

Quote:

Originally Posted by kennedy101

@VAPoorBoy, that's some very nice fabrication and electrical work. Well done sir. Thank you for sharing the dimensions for those of us that might try building the same. I'm curious, did you TIG weld and if so what's the welder you used? Makes me want to get my air compressor setup to use the plasma!

Kennedy,
I unfortunately didn't TIG as I've never tried welding aluminum and I didn't have any argon. The box was built using aluminum angle, rivets and silicon inside. All in seams and rivets have silicon. The outside seams I used aluminum rod and brazed those seams. TIG would have definitely been less work. If I build another one, I'll definitely TIG or use my spool gun. The unit I used for my normal welding is actually the (Titanium Unlimited 200 Professional Mulitiprocess Welder). It's actually a good unit with many options.

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