Thanks D8v3h, I have a heat gun so I'm going to try to do your method.

 

I've also found a DIY method from google:

[video=youtube;ZkjsPrWT0Ic]

 

It's quite interesting and professional, but also scary! He advise people to directly connect to the main plug with 2 wires to provide heat. He doesn't wear electric gloves neither. 1 mistake and it's lethal lol

 

 

Old Dave, I'm quite keen on stress relief on wires. I usually glue gun my output. I'll never do Knot on my wires, but I'm keen on knowing any other method to relief stress and insulate the output.

 

Silicone glue is for now the best choice, but as it's a bit expensive I tend to only use glue gun. I don't like doing that because the glue has some yellowish colour and the result looks so unprofessional.

For a complete isolated enclosure, I'd need to extend the voltage and amperage trim pots on the cover. Any idea what I can use to do that?

Hi The Video shows the mains in the USA witch is 110 volts if you try this with UK mains 230volts it is LETHAL we use 110 volts in the UK for site work via yellow step down transformers Much safer also A legal requirement

 

Frank

Hi cwah

 

for stress / strain relief on the output wires, have a look at this kinda thing..

 

Strain Relief Grommets : Spacers & Grommets : Maplin Electronics

 

Re the trim pots, then drill a small hole in the case that aligns with the pot so an insulated trim tool like this can be inserted.

 

Goot Zirconia Cross Screwdriver for Electronics DIY [E3709] : Electronic Gadgets, Home Gifts & Unusual Novelty Gifts - BestOfferBuy

 

Then pop these into the hole for a nice finish

 

Hole Plug : Spacers & Grommets : Maplin Electronics

Here is a safe PS for you Cwah, if your quick only 2 hours left:

 

FUSION ADJUSTABLE POWER SUPPLY 600 WATT 0-FS-PS600ADJ ((NEW IN BOX) UK WARRANTY | eBay

 

Together with this Lipo charger:

 

http://www.commonsenserc.com/product_info.php?cPath=38_84&products_id=617

Edited September 26, 201213 yr by shemozzle999

Thanks Frank for the warning, I'm going to do it with my heat gun then

 

Old_Dave, your suggestion are really helpful and I'm going to get few mini-screwdriver and stress relief grommets

 

Too sad there isn't anything that could waterproof and be at the same time "removable"

 

 

Shemozzle, I have a 20s lifepo4 with BMS to charge. The charger is never going to work because it's 12s only. And the power supply is probably less safe than mine. I'm using a laptop power supply, these things are double insulated and quite bullet proof.

There are ready made cases available in different sizes and different materials which would be very water resistant.. Not with a high IP rating but good enough for the task

 

I think that Maplins may do them

 

 

Sent from my iPhone using Tapatalk

Couldn't edit my post cos I'm on the mobile, but they are called Project Boxes and may be cheaper / better than making your own

 

 

 

 

 

Sent from my iPhone using Tapatalk

Thanks Old_Dave, I've seen these on Maplin:

Project Boxes : Plastic Enclosures : Maplin Electronics

 

But I talking about the wire output rather than the box. I already have the material for it (thanks to D8veh). With the grommets or strain relief grommets it's not waterproof or dust proof at all.

 

These box have potentially their use if the charger happen to be the right size. But most of the time it isn't.

 

 

Will try to play with the HIPS and see how it goes

Ok, I had a play with these High impact polystyrene sheet and did my first enclosure!!

 

 

As you can see... it's really ugly:

http://usefulandsimple.com/shared_pictures/bike/battery/laptop_charger/HIPS_1st_Draft/20120926_224908.jpg

 

It makes me think about these bodge jobs on cars:

Hilarious DIY car repair bodge jobs carried out by amateur mechanics | Mail Online

 

I didn't really plan for it and litterally wrapped the sheet to the charger. Obviously, it's not very clean and I definitely need to plan properly how I want to shell this charger.

 

 

Haha, the bolts really don't look nice on it! Maybe spray the bolt on white?

http://usefulandsimple.com/shared_pictures/bike/battery/laptop_charger/HIPS_1st_Draft/20120926_224921.jpg

 

 

Just left enough space to keep it the extinguisher safe

http://usefulandsimple.com/shared_pictures/bike/battery/laptop_charger/HIPS_1st_Draft/20120926_224939.jpg

 

 

What I like about these HIPS:

- Very very easy to work with

- I can cut them with a pair of scissor or a cutter

- I can thermo form them so easily. Just get the heat gun on the area I want it to bent and that's it. No bubbles like acrylic or polycarbonate!

 

 

What I still need to do:

- Add the mini-screwdriver to change the voltage and amperage manually.

- Make better rectangular holes. I started with my drill and finished with the small needle file but I think I still don't have the skills

- Add the stress release grommets.. but not sure how it would fit rectangular holes

- Dust proof it

- Add the ground wire

- Make it look more pretty. May have to sand it and paint the bolt?

 

 

I'm not very proud of my first enclosure, and will probably recreate a new once I've finished my todo list because this one is shameful lol

Edited September 26, 201213 yr by cwah

I've also found a DIY method from google:

Good grief. That just illustrates the shonky electrical system in America. You *could* use one of those, but only through an isolating transformer, so you stand some chance of safety. If you bought that kit, you'd have to run it on 110V, so the use of a 240 to 110 step-down transformer is mandatory.

Thanks Scimitar, for now I'm quite satisfied with my heatgun to bend plastic. Maybe later I'll get a kit or go DIY on main outlet, but not on this project