For four years, I have been using a Dynamite Ultra Duo battery charger to keep my machines flying. The Dynamite charger has been a wonderful piece of equipment, but it recently gave up and needed to be replaced.
Instead of buying another Ultra Duo, I decided to get with the program, and build a real charging case. The project started with a Plano brand handgun case from Walmart, which is very similar to the more expensive pelican cases. They are high quality cases and I use them for everything...battery cases, transmitter cases, and charger cases and more.
Next came the power supply and charger. My husband noticed I was looking at them online, and took it upon himself to order a charger and power supply for me for my birthday....how cool was that?
The charger is a Revolectrix Dual powerLab PL8, purchased from Progressive RC. The power supply is a Juice Box (made by Strick Model Products) 1800 watt, 75A, 24volt power supply.
I received the charger and power supply in a few days, and immediately got to work on the case. For the deck lid, I used 1/4" sanded birch plywood. I carefully cut the deck lid out to the shape of the case, test fitting and trimming until I had a perfect fit.
Next, I measured the charger and fans so I could start laying out the holes I would need to cut to mount everything in the deck. Once all the holes were cut, I covered the plywood deck with carbon fiber vinyl wrap which we purchased on Amazon.
Now came the installation and wiring of all of the equipment in the case. That was actually the easy part. Since the charger is flush mounted in the deck, I had to install banana jacks in the deck to be able to plug in my charge leads. I used 60mm 24v fans, which work amazingly well at keeping the air moving through the case,.
The power supply was very easy to secure. I just made a couple of aluminum brackets, padded with loop side self stick velcro to clamp it to the bottom of the case.
I think it turned out fairly well for my first attempt at building a charging case, but I`m sure I will be making a few changes as I discover better ways to do things. So far, it seems to be working great, and I can`t wait to use it at the next helicopter event.
Here is a list of all the components I used:
Case: Plano Gun Guard
1/4" birch plywood
Carbon fiber vinyl wrap
FMA Dual PowerLab PL8X2
Juice Box 1800W, 75A, 24V power supply
Two 60mm 24V cooling fans
Two sets of banana jacks
Two standard balance boards 2s-6s