How to build a solar powered battery box for a van with a few simple tools without being an electrical engineer. This simple battery box powers our 60 quart Arb 12 volt fridge freezer, lap tops, cell phones, and battery chargers. Add a 2000 watt pure sine wave inverter and you can power electrical appliances.
The most expensive component of this project is the battery ($300). The cheapest item is probably the battery box ($8). I built one solar powered battery box for less than $400 including the battery. The second battery box cost over $600 including the battery box. Both battery boxes keep my batteries charged to run my appliances.
One battery uses the CTEK D250S dual battery isolater ($250) to charge my battery off the alternator while driving has an on board MPPT solar charge controller that I use for extended dry camping. The second batter box uses the 30 amp solar charge controller for charging the second battery via solar while driving.
The working solar battery box looks like this:
Start gathering your parts from either Amazon or eBay. Beware of people reselling parts bought on Amazon Prime and resold on eBay for twice the price.
Solar Powered Battery Box Parts List
Start gathering your parts from either Amazon or eBay. Beware of people reselling parts bought on Amazon Prime and resold on eBay for twice the price.
Noco battery box. Buy on Amazon.
80 amp hour deep cycle battery. I bought the LifeLine 12 volt 80 amp hour battery from Invertors R Us for $260 delivered.
4 way Fuse block. Comes with an assortment of fuses and quick connect spade terminals. I am using a 6 way fuse block because it gives me the ability to fuse more items.
160 watt solar panel. About $1 per watt from eBay.
30 amp Solar Charge controller. I bought this PWM charge controller on eBay for $17.
Anderson quick connectors from solar wire to the battery box. $10.95 for a pair from eBay. These are idiot proof. They connect only 1 way.
12 gauge red and black primary wire. You need both colors to prevent mistakes.
Temco Solar solar extension cables. This company distributes some of the finest wire in the industry for cheap. They dominate eBay for quality and service.
Ring Style Wire Terminals 3M Adhesive Heat Shrink Tinned Copper Marine Grade. Available at Amazon Genuine Dealz, or GenuineDealz eBay store.
Quick Disconnect Spade Wire Terminals – 3M Adhesive Heat Shrink Marine Grade. Available at Amazon Genuine Dealz, or GenuineDealz eBay store.
Klein 1005 Crimper Cutters. Amazon. Don’t buy cheap wire cutters.
Dual 12 volt power sockets. Dual USB and 12 volt power sockets. Includes connectors. Ebay and Amazon sell various kinds. I wired 6 plugs in one box for convenience. I never use more than 2 at a time.
How to build a solar powered battery box
- Run the solar power cable extension to the solar charge controller. Follow the wiring instructions supplied by the charge controller manufacture. Negative to negative and positive to positive. I attached Anderson quick connects to the wires coming out from the charge controller to the solar extension cables. The quick connects makes it easier to disconnect the solar panel from the battery box.
- I did not mount the charge controller. I neatly tuck it inside the battery box.
- Wire the charge controller to the battery using 12 gauge primary wire. Crimp 12 gauge heat shrink ring style terminals to the ends of the 12 awg primary wire.
- Cut holes in the battery box for the power sockets. I cut holes in the battery box with a drill and hole saw bit large enough to fit the power sockets. The hole does not have to be perfect as it’s covered by the power socket covers.
- Connect the fuse block. Decide where you want to mount the fuse block. My Lifeline Battery had a place where I safely drilled holes in the plastic to mount the fuse block with screws.
How To Wire The Solar Powered Battery Box
- Cut equal 2 lengths of 12 awg red primary wire. Connect 1 12 awg ring terminal and 1 12 awg quick connect spade terminal to each wire. Connect the spade terminal to the fuse block and the ring terminal to the positive battery post.
- Cut 2 more lengths of red primary that are long enough to reach the power sockets from the fuse block. Crimp heat shrink spade terminals on each end. Connect to fuse block and power sockets.
- Cut 2 equal lengths of black 12 awg wire long enough to reach from the power sockets and negative battery terminal. Connect 1 ring terminal and 1 spade terminal to each end of the wire. Connect the spade terminals to the power sockets and the ring terminals to the negative battery post.
If you feel lazy, Arkpak sells ready made solar power battery packs complete with wires and outlets for about $400. Just add a $250 battery. It has power outlets, battery charger, battery meter, fuses, etc. You still need the charge controller and dual batter isolator. EZ!
Leave a Reply