note: This article first appeared in May 2015.

In Part #1 (posted day before yesterday) of this series I covered the mission of this Ham-In-The-Box project, requirements and limitations, and the initial challenges that I faced. I also outlined each piece of equipment that would make up the final product.

In Part #2 (posted yesterday) of this series I started relating the actual step-by-step build process. I went from prepping the box itself, building the internal frame and getting all the way through installing the remote head to the radio.

In this post I will finish out the building of this project. It was a great project, took much longer than I expected, I picked up some valuable experience and knowledge, and I learned another great lesson along the way. But when it was all over, the project functioned exactly as designed!

Just a reminder of the mission of this project –

To be able to rapidly field deploy a Ham radio, for which I am licensed to use, in the event of any emergency while maintaining a secure and protective storage environment.

~ The “Build” (continued) ~

Step 9 –

This was one of the weirdest parts that I fabricated, the front panel frame. I wanted the frame sturdy, rigid but not heavy. And I couldn’t have it too large or it would get in the way of the fan and other accessories. So I went with 3/4” angle aluminum. While I was measuring the different pieces I found there was a small “notch” or pocket in toolbox’s corner that a piece of the aluminum fit into perfectly. So I took advantage of that and used it to hold the frame in-place and semi-attached to the toolbox. The side benefit was making the whole structural frame kind of like a part of the toolbox without really attaching it. So that is the reason for the one slightly longer side to the frame. If you are looking at the box with the lid opening towards you, the longer leg would go into the notch on the front left side right under the “lip” of the toolbox. I used rivets to secure the pieces.

front view of frame

Then I was working on the solution to attaching the front panel to the frame. I really wanted to be able to remove the front panel to access the components underneath. But exactly how to do that securely while maintaining convenience was a bit difficult to figure out. Then it dawned on me to use JB Weld to bond the bolt heads to the frame. Then it was a matter of drilling out the holes in the front panel to match the bolts.

rear view of frame

Note: The 2″ notch in the front panel frame was not intentional. When I was laying out the frame and the front panel I forgot the “offset” from the left side of the box and didn’t line-up the fan to the frame correctly. I had to cut the notch so the fan wouldn’t interfere with the frame, or visa-versa.

Step 10 –

I really wanted the front panel to look sharp as well as be functional and lightweight. I went shopping for possible materials and found everything expensive. Then a moment of inspiration! I headed off to the local Goodwill and purchased a used VCR with a metal case. The metal that the case was made of was sturdy steel, thin, and a nicely painted black with a bit of texture to it. Perfect!

front

rear

Note: I used masking tape place over the metal to help prevent damage while drilling the hole. I also used a good hole-punch and gave it a sharp whack with a hammer to make a serious starter hole so the drill wouldn’t “wander” when I was starting the hole.

I used Gorilla Tape to finish off the edges and give it a slightly cleaner look than rough-cut exposed edges. Yes, I like Gorilla Tape better than Duct Tape.

The fan had to be positioned directly over the PWRgate to blow air directly at its heat sink, so I had little choice to its location on the front panel. Then I mounted a switch next to it. I figured there would be times when the air movement might not be required so why not have the capability to turn the fan off. When I attached the fan to the back of the panel I used Gorilla Tape around the hole to create a bit of a “stand-off” from the metal panel to make sure the fan blades didn’t come into contact with the metal. The tape also works a little like a rubber washer absorbing vibration from the fan. To cut the hole for the fan I used a hole saw with the correct diameter cutter. Using a hole saw made a much cleaner hole than other methods. The switch hole was drilled out with a regular drill bit as per the instructions that came with the switch.

The next requirement was the “through the case” antenna lead connector. I thought at first about just having it loose and connect it. But then I thought I wanted the box to look as professional as possible so I mounted it on the front panel. The hole for the male-to-male connector was drilled out with a regular drill bit.

Then I positioned my remaining two accessories; the cigarette lighter socket and the USB charging port. I decided to mount cigarette lighter socket lowest on the front panel thinking it might have the heavier item plugged into it. Mounting it lower on the panel might make less weight/torque on panel. The other socket would be for charging USB devices. I figured they would be lighter weight and less of a Wight/torque problem. The larger holes for the cases were cut using a hole saw which made a much cleaner hole than other methods. I use my hole punch to punch a hole through the case and then screwed in the sheet metal screws through the panel.

Step 11 –

Front panel wiring. This is where I struggled just a bit. I am not particularly good with making Anderson Powerpole connections with heavy or real lightweight wire. And my fears proved to be true. I also had to figure out how to distribute the power as well.

I wanted the cigarette lighter socket and the USB charger ports to only be available when working off of shore power not battery power. When on battery power I only want to use valuable battery amps for the radio and cooling fan. So the power to those two accessories had to be “distributed” before sending the power to the PWRgate. For that job I originally choose a Powerwerx Red-Dee-2 Connector 4-way (PS4) connector in a star pattern.

But when I installed it in the box the wires just were a mess and it was difficult to get them into place. So I looked again and saw the same identification for a different part that made a lot more sense. It worked just fine.

I used fuses for each of the cigarette lighter socket and the USB charger port to make sure I protected any devices that I might be using/charging. I chose a simple 15amp glass fuse.

I took this picture to make it easier to see how the front panel was wired. I swapped out the Powerwerx distribution part after the picture was taken. The two heavy 10gauge wires carry the power from the PWRgate to the battery booster. That ensures that the fan will always have power, even if on battery power.

Note: The red tape on the fuse wires is just a visual reminder that they are “hot” wires. I did that since the fuse wires are black.

This is what it looks liked when I put the heavier wires together with their Powerpoles connected. I put zip ties on them to make the wires easier to manage and reduce tension and torque as the wires were being handled.  Don’t get confused, the red/black pair doesn’t attach to the distribution device, it goes from the PWRgate to the batter booster so it always has power. The wires going to the cigarette lighter socket and the USB charger port only have power with on shore power.

Step 12 –

So with all the wiring done it was time to get the multimeter out and check it. When it comes to something like this I check things in stages, only hooking one device up at a time to power. So the only thing that I turned on initially was the AC power supply. I checked its output with the multimeter and it was fine.

Then I plugged in the power supply to the Powerwerx 4-way. Each output worked fine. Then hooked up each of the accessory ports (cigarette & USB), they worked fine. Then the big test, I hooked up the PWRgate. It came on, the right lights were on so all was good. Then the fan test, hit the switch and the fan didn’t work. Turns out I had the wires hooked up wrong. Here is the switch and the wiring diagram.

KC HiLiTES Oval Rocker Switch with Red LED Indicator 30 Amp – Black – KC #3116

Next to get hooked up and tested was the battery booster. All was fine, the right lights were on and all was good. I had to laugh though, when I turned on the AC power supply to make the next connection the battery boost gave the “low voltage” warning signal. Surprised me.

Now the big test, the radio. But before I tested the radio I had to hook up an antenna. You must do that or risk burning up your radio. So I got out my rig. You might remember that rig from my article Antenna Stand and Ground Plane for the Yaesu FT-8900R <click here to read article>

I ensured that the fuse in the radio “hot” wire was good, it was. I hooked the radio up to the battery booster, then turned on the AC power supply. All was good, no smell of burnt wiring. Then I hit the button on the Yaesu FT-8900R to power it up. Nothing, dead as a door nail. I turned off the power, turned it back on, hit the button the radio…nothing.

One time before I had screwed-up the remote head cable which made it not power up. I figured I had done the same thing here. But to get to the cable I had to remove the radio. So I took out the radio and checked the cable, all seemed fine. So I thought I would test the radio before installing it back in the box. Same thing, still dead. I was beginning to worry that I had fried my radio somehow. No………..just me being and idiot. I was pushing the wrong button. I pushed the correct button and the radio powered on. I installed it back in the box, hooked everything back up and right the right button. Bingo! Up it comes and I started scanning and listened to folks having a conversation.

Here is the completed product –

This………

To this………

Note: An additional bonus is finding out that the lid latches act as box “feet” and cants the box up at a desirable angle.

Wiring Diagram –

click to enlarge to full size

I hope the diagram makes sense, I’m not an electrical engineer or anything but I did try to use standards symbols for diagramming it. If you have any questions on the wiring just let me know and I will try and explain it.

Summary –

For me this was the most ambitious Ham radio project I have undertaken since I built the cross-band repeater a couple years ago. And from a “power” perspective it was a little daunting. But I worked through it and figured it out after doing a whole lot of research.

And just so you know, there is a reason that I used this line of Rigid toolboxes. But the exact “why” will have to wait till I get some more time and money. I am always thinking….

2009 - 2020 Copyright © AHTrimble.com ~ All rights reserved
No reproduction or other use of this content 
without expressed written permission from AHTrimble.com
See Content Use Policy for more information.

note: This article first appeared in May 2015.You should read Part #1 that appeared yesterday.

In Part #1 of this series I covered the mission of this Ham-In-The-Box project, requirements and limitations, and the initial challenges that I faced. I also outlined each piece of equipment that would make up the final product. In this article I will cover a step-by-step build process along with tips that I discovered along the way.

Just a reminder of the mission of this project –

To be able to rapidly field deploy a Ham radio, for which I am licensed to use, in the event of any emergency while maintaining a secure and protective storage environment.

 The “Build”

Step 1 –

I quickly realized how inconvenient working on the box would be with the box lid in place. So the first thing I did was take the lid off. To take the lid off get a punch and tap the hinge rod out from the inside out. Once you have about 1/2” of the rod exposed then grasp the rod with a pair of vice grips and pull it the rest of the way out of the hinge.

Next, I laid out the components to ensure they would all fit and be accessible as needed. The PWRgate warned about heat being generated by the unit so I decided to install it off to one side where I could install a cooling fan to blow air directly onto its heat sink. I had to implement a “remote head” installation of the Yaesu FT-8900R due to its overall size. If I didn’t the head would be too close to the lid when closed and I didn’t want to take the chance to damage it. It worked out great since it looks like a much cleaner install. I also took care to install the radio as far away from the heat generating PWRgate to avoid over heating the radio.

Step – 2

I laid out the first level of structural material (framing). I cut the upright 1-1/4” angle iron (aluminum) to fit very snugly into the box. The corners of the aluminum actually bite into the plastic. Once I had the uprights cut to length and placed in the box I then placed the lower cross-member into position based on securing the AC power supply that would be placed at the “bottom” of the unit when the box was placed on its side during operation. That was due to the power supply’s weight; it was the heaviest item that would go into the box.

Next came placing the radio. I based the top cross-member’s position based on the radio unit’s size; I wanted the radio to be up and out of the way. I also wanted the rear of the radio to facing outward for access to the power cable, data port and antenna coupling. That positioning also allows for the fan to move the unit’s heated air to the outside of the box.

Here was an issue I ran into; the radio attaches to the mounting bracket with screws that come from the sides of the radio into the bracket. With the bracket mounted to the cross-member I can’t access the screws to remove the radio from the mounting bracket. So I used the regular screws to mount the radio to the bracket but I used #8 bolts with wing-nut/star-washer to install the mounting bracket to the cross-member. To remove the radio unit you remove the wingnuts and then remove the mounting bracket with the radio attached.

Step 3 –

To mount the PWRgate I used a short piece of 1-1/4” angle aluminum to mount the PWRgate to. I used #8 bolts with wingnuts and washers. I had already marked and drilled holes to match mounting the PWRgate mounting bracket to the cross-member. If I have to remove the PWRgate unit it won’t be easy. The left-hand wingnut it tough to reach with my big hands and fingers but it can be done. Trying to remove the bolts and nuts from the units mounting bracket would have been impossible since the unit itself prevents access to the bolts/nuts mounting the bracket to the cross-member.

Step 4 –

Now it was time to get the AC power supply placed and secured. But as I was looking at that part of the build I was thinking this might be the time I could combine the structural parts. So I measured and placed a lower cross-member and put it in-place to secure the AC power supply. As I did so I realized that could use that same cross-member and the other lower cross-member as the “base” to install the battery booster too. But I had to space the cross-members to match the width of the booster’s base and mounting holes. A little giggling around and I got it all lined up. Then came the challenge to secure the AC power supply to make sure it wouldn’t move around. But, there was a problem that the height of the AC power supply was just a little too tall for the front cross-member. Solution – cut a small notch in the front cross-member to offset the height issue. The side-benefit to doing so was a very secure mount for the AC power supply. All that being said I did cut a small mounting bracket to mount the AC power supply to both the front and rear lower cross-members. That added extra stability to the overall lower structure. Notice I had to cut out some area of the mounting bracket to keep the AC power supply’s cooling vents free of obstructions.

When I was working at properly placing the battery booster I had to ensure that I could mount a “T” on the antenna connection (SO-239) on the rear of the unit. The “remote” outlet is back there as well but I don’t intend on using that option. I did have to ensure that I could see the booster unit’s LED lights and have access to the button on the front panel of the unit. I also had to give consideration to connections on the top of the unit. All-in-all the placement was near-perfect.

Step 5 –

I felt that the front lower cross member was still not stable enough and could move around too much. I also wanted to start putting in the pieces that would integrate the front panel frame into the rest of the structure. I decided the best way to do that was to run a piece of 1-1/4” angle between the front and rear lower cross-members that would run vertical to tie into the front panel frame.

I used 2 rivets to secure the lower part of the vertical support to the lower rear cross-member. But for the front lower cross-member I used a #8 bolt with wingnut and washer to allow the removal of the front lower cross-member that would help me if I had to move the AC power supply.

Also, I pre-drilled the hole that I would use to secure the vertical to the front panel frame. To connect the two I used a #8 bolt with wingnut and washer. This would allow me to remove the front panel frame if needed.

Step 6 –

So now it was time to start actually installing the different components to the structural frame. I started with securing the PWRgate and then the AC power supply. Prior to installing the AC power supply I installed the fused pig-tail to the power supply and making the connection to the PWRgate.

While I tightened down the bolts on the PWRgate mounting bracket, I left the bolts loose on the AC power supply bracket and cross members to facilitate mounting the battery booster.

Step 7 –

I placed a 90° SO-239 connector on the radio antenna to reduce the radical bend in the antenna lead that would connect the radio to the battery booster. Remember the battery booster has a RF sampling port that enables the booster to only boost the battery when the radio is actually transmitting. Receiving doesn’t require or need any boost in battery power.

I also had to make a custom remote head extension cable. It is a 6-wire cable with an RJ connector. I could have bought a cable but making the right length on the spot was easier and cheaper. The cable has to reach from the rear of the radio unit to the remote head.

Step 8 –

One of the easiest parts of this build was installing the remote head mounting bracket. I wanted it fairly low in relationship to my eyes & head. Looking slightly down at a small display screen and buttons is much preferred to looking straight ahead or elevated. I used two self-tapping, self-drilling sheet metal screws with hex heads.

I was going to complete my “build” post today but while diagramming my wire layout I found a flaw and had to do a little re-engineering. Not to worry though, it is coming along just fine, a minor tweak is all. So I will post this part of the build, finish up with Part #3 being the front panel, the wiring, and the antenna.

2009 - 2020 Copyright © AHTrimble.com ~ All rights reserved
No reproduction or other use of this content 
without expressed written permission from AHTrimble.com
See Content Use Policy for more information.

note: This article first appeared in May 2015. It was my first major ham radio and power project. I loved it and learned a lot. Later I wanted a smaller box for my radio and emergency power. That project turned into “Yaesu FT-8900R Go Box &amp; Power Box Together”. But, I am resurrecting this series or articles due to the potential value in showing you what can be done…yeah, giving you ideas for your own project. Enjoy!

So I was talking to my fellow Emergency Preparedness Specialist here locally and we were discussing responding to  emergencies and disasters for our 13 church congregations that we are responsible for. Clearly “communications” was our number one priority; we simply had to be able to establish communications among the leadership over our three-county area in the event of emergencies and disasters. And we needed to be able to do it with or without the “grid” being in-place and functional.

So our Plan C is Ham radio communications using 2m and 70cm for local “tactical” channels and 10m band (28.000 – 28.300) for HF long distance communications. And yes, we have integrated our home-grown repeater into the plan as well. <Click here to read more about the cross-band repeater> But my partner was telling me about his “Ham Go-Box” and how easy it was for him to set-up in the field.

Well, I have my radios stored in hard cases <click here to read more> to protect them against weather and transportation issues. But it was kind of a pain to set one up in the field in a hurry. So I decided to put together my “Ham-In-The-Box” for rapid field deployment.

And as you already know by now, if you are a regular visitor to AHTrimble.com, I am very systematic about my gear, equipment and such. So the first item of business was to define the “mission” for my new project. So here goes –

To be able to rapidly field deploy a Ham radio, for which I am licensed to use, in the event of any emergency while maintaining a secure and protective storage environment.

Here are the Requirements & Restrictions:

1. Radio had to cover the 2m, 70cm and 10m (28.000 – 28.300) bands.
2. Radio had to be easily computer programmable.
3. Radio had to be field programmable.
4. Radio had to be high-quality and reliable.
5. Radio should be able to scan and monitor multiple frequencies simultaneously.
6. The overall combined unit had to be portable enough to be one-handed carry.
7. The storage box had to be secure and protective enough to keep the radio free from damage and environmental harm (within reason) while the radio was in storage or being transported.
8. The storage box had to be easily converted into a deployed radio unit with little effort while maintaining reasonable protection from the elements.
9. The unit had to integrate the capability to operate on both 110vAC shore power and 12vDC battery power.
10. Unit had to integrate a “battery booster” to lengthen operating time.
11. Unit should be auto-switching between shore power and battery power to provide an uninterrupted operating environment.
12. The unit had to maintain box integrity and have no “through-the-wall” connections.
13. Unit didn’t have to be power integrated. In other words, the power (shore or battery) would be provided outside of the unit.

~ COMPONENTS ~

Radio –

So the first thing I had to do was identify which radio out of my stash that I would use. That was an easy choice; my Yaesu FT-8900R quad-band met all the radio requirements. <Click here to read more about the Yaesu FT-8900R radio> The Yaesu FT-8900R is an amazing radio! It is probably the ideal single radio for a “prepper.”

The FT-8900R is a ruggedly-built, high quality Quad Band FM transceiver providing 50 Watts of power output on the 29/50/144 MHz Amateur bands, and 35 Watts on the 430 MHz band. It includes leading-edge features like cross-band repeat, dual receive, VHF-UHF Full Duplex capability, and over 800 memory channels.

Box (container) –

I struggled with this one. My first inclination was an iSeries (Pelican style) box due to durability. But the cost would be very high $300+ and I wasn’t ready to plunk that kind of money down for such a special purpose project. So then I was looking at the various options of military surplus metal ammo cans. I really couldn’t find one that was the right size; and the additional weight of the can was considerable and jeopardized my “portability” requirement.

Then I caught myself in Home Depot doing some tool “window shopping” one evening and came across this line of Rigid toolboxes that are really rugged. They are made out of impact-resin hard-plastic similar to hard-cases mentioned in my series of iSeries radio storage box articles. <Click here to read more> so I really looked at the Rigid toolboxes as a serious option. So for a mid-$30 investment I took a chance. Perfect! It looks as if the box was the right choice for this project.

Rigid Professional Tool Storage System toolboxes are made out of a durable impact resin hard-plastic. I chose the ’22” Tool Box’ it has a lid seal and no “through-the-box” openings to let in dirt, water, dust, etc. It secures really tightly and has a great quality “feel” to it.

Power Supply –

MFJ Enterprises Inc. MFJ-4230MV COMPACT SWITCH (COMPACT SWITCH PS, METER, 4-16V ADJ. 110/220VAC).  This is a great AC power transformer, high quality and very reliable.

This is the world’s most compact switching power supply that also has a meter and adjustable voltage control. Just 5″ W x 2 ½” H x 6″ D, it weighs only 3 lbs. — it is the perfect pack-n-go power supply for field day, DXpeditions, camping, hiking or to pack for your next business trip or vacation to some faraway place. MFJ-4230MV gives you 25 Amps continuously or 30 Amps surge at 13.8 VDC. The voltage is front-panel adjustable from 4 to 16 Volts. MFJ-4230MV also has a selectable input voltage: choose from 120 or 240 VAC at 47 – 63 Hz.

A simple front-panel push-button switch lets you choose either Ammeter or Voltmeter — allows you to select Amps or Volts as you wish to read them. MFJ-4230MV has an excellent 75% efficiency and extra low ripple and noise, < 100 mV. Awhisper-quiet fan cools by convection and forced air cooling. Normal air-flow around the power supply is continuous and a heat sensor increases the fan speed when the temperature rises above 70 degrees Celsius. DC output is five way binding posts on the back of the MFJ-4230MV so you can power your dedicated HF, VHF or UHF transceiver with ease.

Auto-Switch –

Super PWRgate PG40S by West Mountain Radio is a 12 volt backup power auto-switching system rated at 40 amperes continuous from either a power supply or a battery. The Super PWRgate also has a built-in four-stage battery charger with selectable current rates of 1, 4, 7 or 10 amperes. Connected equipment will instantly switch to battery during a power blackout or power supply failure. Uses two 80 ampere Schottky diodes as an OR-Gate to isolate the battery and power supply from each other. Forward voltage drop of less than 0.3 volts at 20 A. Optimized for use with GELLED & AGM type batteries, but will keep flooded lead acid and marine type batteries near full charge as well. Measures 1.64″ x 3.9″ x 5″ and uses Anderson PowerPole connectors.

Battery Booster –

MFJ Enterprises Inc. MFJ-4416B BATTERY VOLTAGE BOOSTER. The MFJ-4416 Super Battery Booster eliminates low voltage problems by boosting input voltages as low as 9 volts up to the desired 13.8 volts. And it does so at up to 25 amps peak with a typical efficiency of close to 90%. It is compact at just 7 3/4W x 4H x 2 1/8D” and lightweight at 1.3 lbs. And the MFJ-4416 Super Battery Booster is designed to be rugged, reliable, and easy to use.

MFJ-4416 includes Anderson PowerPole connectors and high-current 5-way binding posts for both the DC input and regulated output. An internal 30-amp input fuse protects the unit from excess output current demands. There are also selectable limits on the minimum voltage that the unit will accept: 9-volts, 10-volts (default), and 11-volts. This protects you from over-discharging a battery and possibly damaging it. MFJ-4416 also includes output over-voltage crow-bar protection should regulation be lost.

Two additional features offer ways to increase efficiency even more! First, there is an RF sampling port which can be connected to your transceiver`s transmission line with an MFJ-7733 UHF-T connector. When this feature is enabled, the MFJ-4416 is bypassed unless RF is sensed so no regulator switching efficiency penalties are incurred during receive. The second efficiency enhancement feature is a user-adjustable output voltage control which lets you set the output voltage anywhere between 12- and 13.8-volts. When setting the output at 12-volts, input voltages greater than 12V will pass through, but the efficiency of the regulator is higher. And lower input voltage means your transceiver will run cooler!

Typically this unit saves over 30 watts in heat dissipation during transmit, and even 3-4 watts during receive. So it can actually be good to let the voltage sag to 12 volts, then let the MFJ-4116 protect you from lower voltages.

“Extras” –

USB Charging Ports –
Powerwerx Panel Mount Dual USB Socket 3 Amp Device Charger. Dual USB device charger features 2 USB ports with high charging output. Compatible with Apple and Android products and more. Fits standard 1-1/8″ diameter hole. Maximum output current of 2.1A per single USB device. 3A maximum total output.

Cigarette Outlet –
Powerwerx Panel Mount Cigarette Lighter Socket Automotive Marine Grade. Panel mount receptacle is made out of marine grade materials and can be panel mounted in two ways. By utilizing the flange or the slim method by utilizing the large locking nut. The receptacle features a watertight sealing cap, and is easy to install.

Cooling Fan –
After reading about the potential of heat being generated by the auto-switch I decided I wanted a cooling fan option (switch controlled) to be able to drive air directly at the PWRgate unit’s heat sink.

Computer CPU Cooling Fan; Rated Voltage : DC 12V;Fan Speed : 3000+/-10%RPM  Air Flow : 32CFM;Noise : 23.85dBA;Bearing Type : Hydro Bearing Size : 70 x 70 x 15mm / 2.8″ x 2.8″ x 0.6″(L*W*H)

~ The Challenges ~

The Biggest Challenge –

More than all the other challenges combined was the fact that I really have little to no experience assembling, wiring, and configuring Ham radios. Yes, I built the cross-band repeater than I mentioned earlier, and it works great, but this seemed like a far more complex project. And I was worried I wasn’t schooled enough to succeed. So I reached out to a few more experienced Hams (Elmers) and asked for their feedback on my configuration and wiring design. No of them felt I was going to burn the house down or fry my equipment.

First Challenge –

The first challenge I ran into was how to mount the internal components without adding a bunch of weight to the box. I ran down the list of various construction materials and it became obvious that aluminum was the only logical choice for this project. So off to Lowes I went. I quickly figured out their stock aluminum pieces would work out just fine so I purchased a variety of pieces such as angle iron and flat stock. I simply cut and drilled as required.

Second Challenge –

I really didn’t want any holes through the box itself. I wanted to maintain the integrity of the box and be able to reuse it later if the radio idea didn’t work out. So I made the decision to not actually connect the construction materials to or through the box itself. All the mounting pieces would simply be a tight fit; tight enough to hold the entire support structure in-place with no actual mounting to the box itself.

Third Challenge –

How to get everything into the box and mounted in such a way that I could access each component piece for adjustment, replacement, or repair. There was no easy answer to this challenge so I just started laying out the pieces in the box till they started to “fit” into place logically. It was like playing 3D chess.

Fourth Challenge –

I had to figure out how to connect the construction materials together to allow some changes and modifications as I went. And to ensure that I could relatively easily access each component should the need to arise. I decided that the base/first level of the insides would be riveted together to ensure stability. After that the upper levels would be bolted using regular hex-nuts or if, greater ease of access was needed I would use wing-nuts. To hold the front panel on and yet make it easily accessible I decided to use JB Weld to hold the bolts in place. The bolts then pass through the front panel and are held into place by wing-nuts. All nuts backed with external tooth lock washers. All bolts are #8 to make it easier by using a single sized bolt, nut, and washer.

Fifth Challenge –

This was a very easy challenge to resolve. I wanted to make sure it was all compatible with everything else I have. So all the wiring had to be Anderson Powerpole compatible.

2009 - 2020 Copyright © AHTrimble.com ~ All rights reserved
No reproduction or other use of this content 
without expressed written permission from AHTrimble.com
See Content Use Policy for more information.

note: I started working on this article back in 2017 but due to the “crash” it got put on hold. I finished this article over the last couple of weeks.

What I was looking for in a AA & AAA battery charger was two-fold, ability to charge AA & AAA batteries; 1) using 110vAC power when it is available, 2) using 12vDC power for emergencies or field use. Of course, using the same actual charger, just changing the charger’s power supply. And the 12vDC option could come from a power box, solar charger, battery, vehicle accessory port, etc.

You may be asking why both voltages…legitimate question. I want the capability to charge my batteries under normal conditions and as quickly as possible…hence, 110vAC power capability. But, if the regular utility power goes out I want multiple ways to be able to charge my batteries; 1) using my portable Honda generator (110vAC), 2) 12vDC power available through car batteries, 3) my various portable power box, 4) solar panels.

“Redundancy” being a priority to me. The old “Two is one, one is none, three is a good start” mentality.

Mission Statement –

“Ability to charge standardized field operation batteries via 110vAC or 12vDC power.”

Requirements & Restrictions –

1. Must be able to operate on 110vAC power for extended periods of time without damage to the unit or the batteries.
2. Must have the capability to operate on 12vDC without modification to the unit.
3. Must be able to charge AA and AAA rechargeable Ni-MH and Ni-CD batteries.
4. Must have sufficient safety features to prevent damage to the batteries, the unit, or the area around the unit.

Test Units –

• FrePow 8-slot
• Tenergy TN160
• Foxnovo F08
• AccuPower IQ-338
• BlueTech AV-1000
• MaximalPower FC1000
• Ansmann PL8
• SunLabz SL00056

Each unit was tested against the Mission Statement, Requirements & Restrictions, and comparing features; price was not so much of an issue. Units were tested recharging batteries via 110vAC and 12vDC. The 12vDC test was done via a 110vAC -> 12vDC power supply to ensure no variation in power such as solar power fluctuations or 12vDC battery charge level or condition. The purpose of the testing was to test the charger unit itself not a solar panel / charger combination. I did test with a 12vDC solar panel test just to ensure compatibility and that it would in-fact work. These test units all ranged from being able to charge 4 batteries – 16 batteries.

FlePow –

No longer available – Testing results not included.

Tenergy TN160 –

Compact, sleek, and good looking unit. Nothing fancy about this unit and no frills or thrills. Both size batteries (AA &  AAA) were easy to insert and were held steady in the charger tray. Each charging station assessed the batteries individually and began charging within 5 – 6 seconds. The LCD screen was easy to read and made sense without any directions or instructions needed.

From the manufacturer:

• 12 channels PWM switching fast charger with MUC control; accurate voltage detection ensures no over-charging and under-charging
• 12 independent charging channels for individual charging and detection: AA & AAA, NIMH/ NICD can be mixed when charging. AA & AAA, NIMH/ NICD can be mixed when charging.
• 8 hours safety timer ensures extra safety.
• Over-heat, over-current, short-circuit, & reverse polarity protection, (mechanically) ensures that charger and batteries will not be damaged when users insert batteries with reversed polarity.
• Large LCDs indicate charging status.
• Charger comes with refresh function
• Input: 100-240v AC (Works Everywhere in the World).
• Suitable only for 1.2v AA/AAA NIMH/NICD batteries.

I really like the automatic protection built into this unit, especially the safety timer that shuts down the unit after 8-hours of operation. During testing the batteries never got hot and that is a really good thing. Heat is what damages batteries more than just about anything (operating environment) else. The unit won’t recognize damaged or fully discharged batteries which isn’t particularly good.

Foxnovo F08 –

This thing is a hunk of plastic and electronics, there is nothing sleek or compact to it. There is no fancy LCD screen to look at, simply a series of flashing status lights. When I was inserting the batteries (AA & AAA) it wasn’t the easiest thing to do. First off you have to move the spring-loaded negative contact manually to get each battery to seat in the charging cradle. And here is the stupid part…the positive contact is this little “nub” piece of metal. If you look at the positive contact on a battery it too is a little “nub” of metal. Try putting two little “nubs” together and see how that works for you! It was fairly easy to bump one battery while inserting another. Bumping a battery more than just a minimal amount and the positive “nub” contacts decontacted. Yes, decontacted is a word I made up. Once the batteries were all in-place they were fine.

From the manufacture:

• Capable of charging 8 batteries of different sizes, types and capacities at the same time; Each of the eight battery slots charges independently
• LCD indicators lights shows the charging process of every batteries
• Automatically identifies Li-ion, Ni-MH and Ni-CD rechargeable batteries.
• Automatically detects battery status and selects the appropriate voltage and charge mode. Automatically stops charging when complete
• Come with a US-plug adapter for indoor use.
• Adopts negative voltage control technology to improve charge efficiency.
• Excellent features of heat dispersion and reverse polarity protection. Protect opposite connection and short circuit, 0 voltage alarms
• Compatible with batteries: Li-ion 26650, 22650, 18650, 18500, 18490, 17670, 17650, 17500, 16340, 14500, 10440, Ni-MH and Ni-CD A, AA, AAA, C, SubC

Here’s where this unit is way cool…charging time. And no, there wasn’t any noticeable battery heat indicating that the higher charging rate was damaging the batteries.

And then there are additional cool features to this charger; 1) charges a long list of Li-ion batteries, 2) charges C, SubC, & D size batteries. That makes this unit considerably more versatile than the other units tested. If you are wondering about the Li-ion feature I can tell you that is will recharge the rechargeable version of the CR123A (RCR123A). The CR123A is a popular battery for flashlights and weapons’ optics.

The testing showed that the unit charged all the batteries of different brands and sizes in record time. It only took the unit a matter of 2 – 3 seconds to analyze the batteries current charge and begin the charging process. There is no fancy LED screen to indicate much of anything. There is a series of four lights that shows current charge. They flash to indicate that charging is taking place at a specific level (25%, 50%, 75%, & 100%). When the battery is fully charged all four yellow lights glow steady.

Periodically a blue light will flash in the upper right-hand corner on the face of the unit. I have absolutely no idea what that means. So you wonder why I didn’t refer to the instructions. Ah, there aren’t any. Yup, no instruction guide of any kind with the unit. I searched all over the Internet looking for a user guide and nothing. But, fortunately the unit is pretty simple to use…so instructions aren’t really needed.

AccuPower IQ-338 –

This unit is sleek, compact, and way more intelligent than me. Yeah, surprising…right? Seriously, this unit has a ton of options for you and your batteries. The batteries fit in this charger like a glove, very nice engineering. The LCD screen is easy to read and back-lit as well.

From the manufacturer:

• Fast Charge Li-ion or NiMH/NiCad Rechargeable batteries including most common 18650 size.
• Test Li-Ion & NiMH/NiCad cells for actual capacity.
• Automatic selection of NiMH/NiCad or Li-ion chemistry cells.
• For use with the following: NiMH/NiCad: A, AA, AAA, sub-C, C-baby size
• Li-ion: 26650, 22650, 19650 (protected 18650) 18650, 17670, 18490, 17500, 17355, 16340 (RCR123A), 14500, 10440
• With the new AccuPower IQ338 charge or test most round cell batteries. Automatic selection of NiMH/NiCad or Li-ion chemistry cells. Includes the most common 18650 cells, can accept cells up to 70mm in length. Easy to use, easy to program, informative display.
• Four independent channels programmed individually.
• Easy to read large Backlit LCD display.
• Digitally displays battery information.
• Adjustable charging rate from 300 to 1000 mA.
• Three modes of operation:
  • Charge
  • Fast Test
  • Nor Test (Normal Test)
• Delta Peak full charge detection for NiMH/NiCad cells.
• 4.2V full charge for Li-ion cells. CC/CV charge profile.
• 12V input powered and can be powered by an optional car adapter.
• Worldwide voltage switching power supply.
• Automatic detection of different battery type. NiMH/NiCad Vs Li-ion.
• Thermal sensors to protect against overheat and overcharge.
• USB charging socket. Supplies 5V 1000 mA.

So I figured out that this unit is actually a computer that also charges batteries. OK, on a more serious note, this is a great charger. However, it only has four slots for batteries. I wanted the ability to charge more batteries at one time than just four so I took some time and looked online to see if it has a bigger brother. It does, but the bigger brother is not the IC-338 with more slots, it appears to be a carbon copy of the Tenergy unit.

And unlike the Foxnovo unit, the AccuPower unit does come with instructions…very, very good instructions. It explains how to take advantage of each unit feature.

I like this unit, just wish it handled more batteries at one time. But…I really like this unit.

The latest version of this charger is the AccuPower IQ-338XL. The “XL” evidently added more battery size capability and higher charge rate which lowers the charge time.

BlueTech AV-1000 & MaximalPower FC1000 –

You might be wondering why I am grouping these two chargers together for review purposes…GREAT QUESTION!

Simple answer…they are the same unit other than a different name on them. Although there are two units being tested, I will refer to them as “unit” for the purposes of this article. I will only refer to the MaximalPower FC1000 unit since it is the only one of the two that is still readily available.

The unit solidly built, sleek, and compact. Good feel to it. The LCD was clear and easy to read.

From the manufacturer:

• FC1000 Intelligent AA/AAA Charger and Capacity Tester with USB charging port
• Battery charger for NiCd and NiMH AA and AAA rechargeable batteries
• Features 4 function modes: charge, discharge, refresh, and test
• Overheat-detection to prevent over-charging
• 4 separate LCD displays for simultaneous readouts

The unit worked as stated in the description. I liked the fact that is displayed the individual “mAH” of each battery in the LCD display. It was also nice to have a USB charger as well, especially a 1A USB charger. Only being able to charge 4 batteries at one time was a drawback. Unfortunately I couldn’t get real excited about this charger.

Ansmann PL8 –

Nice basic “brick” recharger unit. Has overcharge protection but I didn’t see any smart overheat protection, but it does have a built-in time shutoff to help prevent overheating. The 500mA charging current helps charge your batteries quickly, but it completes the charging cycle in a “trickle” mode to help ease the potential heat buildup problem.

From the manufacturer:

• For 1-8 AA/AAA (NiMH/NiCd) cells
• Discharging of the batteries before charging is possible, Multi-coloured LED indicators show the battery status for each charging slot
• Individual supervision of each cell, Multiple over-charging protection per cell and Automatic cut-off (-dV) & Trickle charging
• Faulty cell detection / accidental alkaline insertion detection
• Reverse polarity protection

Single use battery detection (i.e. alkaline batteries) prevents any chance you might accidentally try to charge the wrong types of batteries. There is a “discharge” capability to reset the battery’s memory to a fresh state. I like units with the more informative LCD displays, but this unit’s flashing light display of this charger unit gives you all the information you actually need. The USB charging port is a nice little extra.

Going back to the “trickle” charge feature. One of the nice things regarding this feature…self-discharge offset. You can leave the batteries in this charger and the trickle charge feature will keep them fully charged but not overcharge them. That will offset any self-discharge of your rechargeable batteries. And I really like that each charging port is individually monitored and each battery “smart charged” individually to its own capacity.

I would love this charger if it had 12vDC power capability but it only runs off 110vAC. And that gives it a “fail” compared to my mission statement. But, if you are looking for a 110vAC only unit…this is a great option.

SunLabz SL00056 (MOSL00056) –

This unit suspiciously looks a whole lot like the Tenergy TN160…with 4 additional battery bays.

From the manufacturer:

• 16 INDEPENDENT CHARGING SLOTS – Allows you to mix and charge AA / AAA / NiCD / NiMH 1.2v rechargeable batteries.
  
• SMART AND SAFE – Accurate voltage detection ensures no over-charging and under-charging.
• Reverse polarity protection and 8-hour shut-off timer ensures extra safety.
• LIGHTED LCD DISPLAY – Intelligently shows the charging status of each rechargeable battery.
• 1 YEAR WARRANTY
  
• SAFETY WARNING: The charger should not be plugged into an outlet with batteries for extended periods of time to prevent damage. Remove the charger from the outlet once the batteries are charged and use the recommended charging times in the manual.

Each battery is charged individually based on its own state of charge. There is “discharge” capability to reset the battery’s memory to a fresh state. Nice to clear battery memory and revitalize batteries.

I don’t like that you can’t leave the charger plugged in with batteries in charger. So this tells me there is no overheat protection…and the potential for battery damage. I don’t like that this charger gets batteries fairly hot. As long as you monitor the charging process this is a decent no-frills charger. And it charges 16 batteries at once!

Comparison Chart –

Summary –

Let’s clear up one thing right off the bat…The FlePow and the Tenergy chargers are made by the same company in China, SunLabz.. SunLabz simply does what’s called “private label” manufacturing. In addition to SunLabz selling their own chargers they market them to other companies such as Tenergy who then sell them under their brand.

The ability to charge the other types and sizes of batteries could prove to be a real benefit in long-term emergencies and disasters. In terms of grid-down, the ability to recharge the rechargeable CR123a batteries (RCA123A) could prove really valuable. It should be noted that I am NOT a proponent of the CR123a batteries (rechargeable or standard), I only use and recommend AA & AAA batteries.

I can’t recommend the FlePow unit because it is no loner readily available.

I can’t recommend the Foxnovo unit, it simply cooks the batteries with too much heat and is no longer readily available.

I don’t recommend the Maximal unit because…well, I just couldn’t get excited about it…something just seemed off about it.

The only reason I don’t recommend the Ansmann unit is it doesn’t have a 12vDC power option. If I was only going to use AC power this would be my #1 choice.

I liked the Tenergy unit but it is a “private label” charger unit made by SunLabz. This is a unit I use and would buy again. And yes, I put the SunLabz unit in this same category. These are not high-end chargers…but solid and get the job done.

The hands-down winner is the AccuPower IQ-338 unit!! But, I would NOT buy it. I would buy the newer version AccuPower IQ-338XL to take advantage of more battery options, etc. The only drawback is the number of batteries it charges at one time…4. But this is simply the best charger…my “go to” charger.

However………….if I was only going to use AA & AAA and an occasional C battery…AND I needed to charge more than 4 batteries I would go with the AccuPower IQ-312. That bad boy can charge up to 12 batteries at one time. It is also 4.7 star rated on Amazon. If I wanted a 16 bay charger for AA & AAA batteries and an occasional 9v I wouldn’t hesitate to go with the AccuPower IQ216.

So I own and use the Tenergy charger, the AccuPower, and the HiTech IC1012. I didn’t test/include the HiTech IC1012 in this article because the technology is 7 years old and the unit is no longer available.

Are there other good units out there? Yup! Should you buy any of them? No idea! I can only tell you my experience and what I use…and I am happy with my choices…they are all still working and doing a good job.

If you are interested in buying any of the chargers I use I will provide the links to Amazon. If you click on the link I provide I might make 1% or 2% as a finder’s fee from Amazon. Hey, every little bit helps in this day and age. If you don’t use the link that’s no issue. I hope you find that battery charger that you need and that it serves you well.

AccuPower IQ-338 $47.24 <click here to buy on Amazon>

AccuPower IQ-338XL $53.45 <click here to buy on Amazon>

AccuPower IQ-312 $37.97 <click here to buy on Amazon>

AccuPower IQ216 $32.30 <click here to buy on Amazon>

Tenergy TN160 $47.99 <click here to buy on Amazon> (you also get 12 Premium Tenergy AA rechargeable batteries)

SunLabz SL00056 $44.99 <click here to buy on Amazon>

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