Inverter

A Victron Phoenix 12/800 inverter that I have dismantled and built into my standard go-kit box size for portability. This clearly voids the warranty (if you intend to do this or similar yourself) but means I can carry the box in more scenarios and also waterproofs the inverter while not in use.

In addition to the standard wire connectors, I added dual 45A PowerPole connectors which are wired to the same input lugs as the wire terminals and go through the built in fuse. At nominal 12.8V LiFePO4 battery voltage, this gives 1152W input across the two 45A connectors which is enough for the 800KVA inverter. The battery has 2 45A connector outputs and a BMS which is capable of 90A output (though the battery cells can do 100A). I have 2 short heavy duty cables also with 45A PowerPole connectors on each end specifically for use with the inverter though smaller ones are fine for small AC loads.

I also added the VE.Direct Bluetooth module which lets me control the inverter via my phone in the field if necessary.

Box

This was an interesting one to try and build into a box because with the large transformer coil, I wanted it to be permanently attached to the base of the case. That meant that the panel and other connecting parts needed to be separate so I could firstly mount the coil while still having some access to the inside of the case and secondly open the case in future if needed. I used Fusion360 for this to design all the parts together which was a great learning experience.

The transformer coil sits on a kind of sled which it is bolted to using the bolts from the original case. This is then stuck to the bottom of the case using "No more nails" tape which I've found to be quite permanent!

The DC side sits in something of a rectangular box which gives the board support. I had wanted to have an enclosed box on 4 sides to force the fan airflow over the heatsinks, but after a second 9 hour print that didn't slide on correctly because the bottom of the DC board is wider than most of it and the front panel needs to be put on first so the switch can be soldered back in place and the wire connectors and PowerPole wires reattached with access for a screwdriver, I took a hacksaw to the top size and cut out most of the panel! It still gives good support, but has enough flexability to bend on around the bottom of the board and up into place.

The AC socket, AC output board, PowerPole connectors and Bluetooth dongle all have small brackets to mount them to the main panel.

Going from the DC input to transformer coil, the 6 wires were removed, flipped and their connectors bent 90 degrees to allow them to sit at the correct angle within the box as the DC board and coil now sit at 90 degrees to eachother instead of inline as in the original case.

Ventilation is not as good as the original case being that there are less holes and the air will go down and back up. I don't intend to ever run this hard enough for that to be a problem but it's always a consideration.

The ground cable is left unconnected to anything inside. It was mounted to the metal case in the original casing. I may at some point add a connection lug for ground above the AC output socket.

Gear

CAD Parts

Part Download Notes
Main Panel MainPanel.stl
AC Panel Mount ACPanelMount.stl Requires 2 M3 square nuts and 2 M3 bolts.
AC Socket Mount ACSocketMount.stl Requires 2 M3 square nuts and 2 M3 bolts.
DC Box DCBox.stl Requires 4 M3 square nuts.
DC Control Panel DCControlPanel.stl Requires 4 M3 bolts through main panel to DC Box nuts.
PowerPole housing PPHousing.stl Requires 2 M3 square nuts and 2 M3 bolts for panel mounting and 2 additional long M2 bolts to hold the PowerPole connectors. Print could be modified to have a friction fit of PP connectors instead.
Coil Sled CoilSled.stl Drill holes in the center to mount the Coil bolts through. Stick to the case with strong double sided tape (I used "No more nails" tape)