Preparing the Container
Making Modifications to the milk crate.
If you ordered in the light I suggested and the switch for an additional light without a on/off switch along with a few other holes that will need to be drilled these preparations are necessary.
As you can see, the led light is quite large and needs to be fitted into the milk crate. I set it on the bottom giving a nice glow as well as lighting the pathway floor.
Led light https://amzn.to/3LhXzDr
First, lets look at all sides and decide which side will be the front and the rear of the box.
Milk crate https://amzn.to/3LatCoX
The led light and place it on the lower end of the milk crate, on the side that you will want to be the front. Center the led as best as you can and you will see it over laps some of the tabs but most of this area is flat as well which is handy.
Thae your razor blade knife (box knife) being careful, make a small notch around the led light fixture. The top should have 4 notches and the bottom should have 4 notches. When we have the notches made we will then carefully tilt the led up to its side and mark the center where the wires are so later we can drill a hole at this center mark.
Now, you can take and move the led light aside and where you cut the notches into the tab I want you to make a clean cut through the tab bottoming out to the flat bottom. Then, take at a small angle from inside the cut a few fractions of an inch and then cut diagonally to meet with the bottom. You should have a triangular shape piece easily removed. Do this for the other seven remaining notches.
Now that we have all notches cut we have to remove the center part -- between the two cuts we made to let the led lamp fit in. The easiest way I found was to simply take a pair of pliers and from one end bending the tab back and forth through the entire cutout and it will simply break off. Do this for all 4 areas and use the box knife to clean up any remnants that will not let the led light sit flat.
Remember in the center we made a mark for the hole to fit the wires through. Take a 3/16 drill bit and drill a hole where you had made the mark. Keep the drill and 3/16 handy we will use it again.
Now, we should be finished with the bottom led light, place the wires through the center hole and fit the led light into the areas you cut, it should fit nice and snug. If not, use the knife to make any small adjustments. Now that is sitting flush take some of the two sided tape and adhere the led light to the crate.
double sided tape https://amzn.to/3waEuPf
You may find it is not as secure as you want it, so in two different places drill holes on top and bottom on the two sides of the led light then take the small zip ties. feed it through one end of the hole, around the led light and back through the crate then connect and zip it up to tighten.
Zip Ties https://amzn.to/3Le3jhN
The next item we will concentrate on is the on/off master power switch. This shuts down all power and also places one rule into usage of the gen. Always turn it on even if charging first especially before connecting to the solar panel. The nice thing is its easy to store with the master switch off, the only draw from the battery is the volt meter.
On/OFF switch https://amzn.to/3yBT0Bw
for this adjustment to the crate we will need a simple 12mm hole saw and drill and a box knife. We may want to take our inverter since it is planned to go into the adjacent side up flush and mark how far it comes from the side wall inward. Now, from inside the case drill the 12mm hole all the way through. On the front side you will see there are remnants of the tabs that we will need to trim out so the bolt can tighten and move easily. once the debris is removed slide the switch from the inside part of the case toward the outside. Use the washer and nut and tighten. The switch should be secure and stationary -- it will get plenty of use.
Next, on the opposite side if you had a usb light bar and want to add it to the top we will need a switch and holes to use zip ties to attach.
On/off switch https://amzn.to/3syDy5l
USB Light Bar https://amzn.to/3LcpbtK
19mm 3/4 inch hole saw https://amzn.to/3yxGMK4
This usb light has 2 choices of setting one up. The first way is quite convenient, you could take the light bar, situate it up top and drill four holes to connect the light bar to the crate and then snake the usb connection inside the case. Later on, if you ordered or are using the solar charger I recommended plus many others it has a usb connection. We will connect it then.
Second way allows a wee bit more freedom in case you want to change it to a different light bar later on we will have the switch already built in and the wiring is quite simple.
Here we will take a 3/4 inch hole saw and drill a hole like the other from the inside going out. You will need to take your box knife and trim for the out ridge of the switch itself to fit flush with the flat surface and then simply push the switch into the hole. It will take a little effort but will go in and be sturdy. Next, lets take the led light and place it where you wont on top by the switch. Mark 4 holes towards the ends of the light one above and one exactly below. To the left before the switch and next to the end we will want a hole to snake the wire from the led light through the case. Now, lets do some damage to the led light. Allowing some cable we will take and snip the cable so the switch and usb connector are removed. Then snake the wire through the hole and then take 2 zip ties snaking them from behind and around the led light bar and then through the corresponding hole be it from top or bottom starting and then zip it until it is snug.
We are almost finished with our preparation. 2 small other changes and then one last thought and then we are ready to put the battery in.
Take your solar controller and place it up on the inside top front corner or wherever you want to place it.
Renogy Wanderer Solar Charger https://amzn.to/3weqUL3
As you can see there are 4 holes in the wanderer base to connect it with. We will only use two. With the wire connections facing toward the back of the crate the two holes we will be using will be the upper left and lower right. Take your 3/16 drill bit and run it through those two holes to widen it a bit. Next, place the charger up where it will be installed, with the wire connection facing to the back and mark the upper left hole to the crate. Drill a hole. Thats all we need to do for now with the controller and you can set it aside.
Here we will want to take the Styrofoam I told you about, measure indie dimension and cut the foam to size.
Place it on the bottom so it lays flat. The reason I chose Styrofoam is because it is almost weightless and won't add much to the weight plus it is easy to cut as well as some waterproofness to it as well. You could use plastic or plywood, its your choice. It is just nice to have a flat surface and nothing getting into the generator from the bottom.
Once it is placed flat on the bottom, we will then take your battery and place it to the back of the crate. Its up to you where you want to place your battery, however, for even weight distribution and easy carrying I just centered the battery in the middle of the back wall of the crate.
BatteryEvo 12v28ah code guardianwill https://batteryevo.com/battery-evo-12v-28ah-lifepo4-battery-ef1230-360wh-solar-rv-golf-cart/
When you have it placed take a yellow marker or simply mark where we will drill 4 holes to connect the battery to the crate so movement is restricted. About 1/2 inch from the bottom on both sides of the battery and 1/2 inch from the top and again on both sides of the battery. Later, We will be connecting it
If you can help, we would truly appreciate and need it -- Thank you https://gofund.me/5b4a16c6 Any little bit helps and we truly are grateful.
Well we are done with the modifications to the case and are now ready to put it all together.
Dimension:
2028 x 1525
File Size:
186.92 Kb
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