Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Converting Cargo Trailers into TTTs

Re: Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Postby bdosborn » Sun Apr 18, 2021 8:52 am

That will be a great system, wait till you start charging with PV. You get at least 15% more charge accepted over lead acid due to the lower internal resistance of Lithium as well as the ability to maintain full charge current until fully charged (no absorption stage). :thumbsup: :thumbsup:
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Re: Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Postby flboy » Sun Apr 18, 2021 12:45 pm

Thanks. I am anxious to try it out with solar.

Put it on the scale all together and it weighs 51.9 lbs. If I recall, each of my golf car batteries were 54lbs.

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Don (Flboy)

YouTube Video of Finished 6x12 Trailer:
https://youtu.be/6_-8cVdWUIA
YouTube Video of 7*18 with 2ft V-nose Trailer:
https://youtu.be/MUcMM86LA2g
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Re: Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Postby featherliteCT1 » Sun Apr 18, 2021 4:37 pm

Thanks for taking the time to check the sine wave quality on your inverter.

I think your battery bank is AWESOME!

What gauge of wire will you install on your pos and neg posts and what are the maximum amp hours you expect to draw from your bank?
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Re: Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Postby flboy » Sun Apr 18, 2021 9:32 pm

featherliteCT1 wrote:Thanks for taking the time to check the sine wave quality on your inverter.

I think your battery bank is AWESOME!

What gauge of wire will you install on your pos and neg posts and what are the maximum amp hours you expect to draw from your bank?


Thanks and you are welcome. Hope the O-scope pictures showed you what you wanted to see.

I have a 150A BMS which is capable for 150A continuous. I did not go larger mainly because the form factor changes and I would not have been able to fit it into the group 27 case as well, also, that is ~1,950 watts and I have nothing that will need that much power. Fridge runs 24 hours/day and draws 60W, and the microwave is only 1,000W. Other than that... I'd manage loads.

So I will get a gage wire to handle 150A continuous.. probably a 1/0 gage. I need to change out the main positive lead in the battery to match the BMS P- lead in any case. It was all I had at the moment and it is a gage smaller.

As far as how many amp hours I will draw, it will depend on the solar situation and the circumstances related to running the generator. In the absence of solar keeping up... I will probably take them down to between 30% and 50% and that will just be so the Generator can run for shorter periods.
Don (Flboy)

YouTube Video of Finished 6x12 Trailer:
https://youtu.be/6_-8cVdWUIA
YouTube Video of 7*18 with 2ft V-nose Trailer:
https://youtu.be/MUcMM86LA2g
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Re: Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Postby bdosborn » Mon Apr 19, 2021 9:55 am

I like marine wire, Ancor is what the sailor guys seem to use a lot. I've been testing my battery with 1000W AC through #2 marine wire (100A DC for 3 hours) and it stays cool as a cucumber.

Here's how to size it:
http://circuitwizard.bluesea.com/#
Here's what I would use if your inverter is 5' or less from your battery for 150A:
Amazon Linky #2 Ancor

I'd throw a MRBF terminal and fuse on your battery; I don't trust Chinese BMS to work with the high fault currents LiFEPO4 batteries are capable of.
MRBF Terminal fuse

Bruce
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Re: Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Postby flboy » Mon Apr 19, 2021 10:07 am

Thanks Bruce. I agree on the terminal fuse. That is a good idea. I have used those before. I will add that when I replace battery post hardware on each LiFePo4 cell. . I don't like the way the posts work and I am going to buy some new hardware with lock washers.


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Don (Flboy)

YouTube Video of Finished 6x12 Trailer:
https://youtu.be/6_-8cVdWUIA
YouTube Video of 7*18 with 2ft V-nose Trailer:
https://youtu.be/MUcMM86LA2g
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Re: Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Postby flboy » Mon Apr 19, 2021 12:29 pm

I have the crimp tool and copper terminals, so I picked this up on sale for $29.99. I'll cut what I need out of this to make cables for 150A. 40ft of 2ga.. that is cheap and should do the job, especially since 150A will be rare peak and typical will be about 60a or less. Copper coated aluminum is not ideal, but will work fine in my application and price is too good.

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Don (Flboy)

YouTube Video of Finished 6x12 Trailer:
https://youtu.be/6_-8cVdWUIA
YouTube Video of 7*18 with 2ft V-nose Trailer:
https://youtu.be/MUcMM86LA2g
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Re: Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Postby featherliteCT1 » Mon Apr 19, 2021 6:44 pm

I just watched your youtube video about your set up and how you tested for capacity

https://www.youtube.com/watch?v=RzfH5qx9zps

Thank you for posting this video and documenting on this forum how you did it. I am soooo grateful!

I want to buy some LIFEPO4 cells but do not need them for a while because my lead acids are still in great shape. However, I would like to have some LIFEPO4 cells now.

I am debating about whether to buy some and build a bank now but just leave them maintained on the shelf for a couple of years before I need them.
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Re: Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Postby flboy » Mon Apr 19, 2021 7:22 pm

You are welcome. I enjoy doing it. Hope it was helpful. Hard to get everything in and keep it as short as possible.


Building your own is affordable. I built this for my new CTC, but I am really tempted to build another for my other CTC and shed 150lbs of hitch weight, but my lead acids are good too.

Maybe I will reconfigure the existing CTC with quick disconnects and just move the bank to whatever camper I am using. It is only 52lbs and portable.

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Last edited by flboy on Mon Apr 19, 2021 10:51 pm, edited 2 times in total.
Don (Flboy)

YouTube Video of Finished 6x12 Trailer:
https://youtu.be/6_-8cVdWUIA
YouTube Video of 7*18 with 2ft V-nose Trailer:
https://youtu.be/MUcMM86LA2g
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Re: Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Postby flboy » Mon Apr 19, 2021 7:30 pm

Still working on my portable power pack that I built the 25aH LiFePo4 cell for. I dismantled a Bestek 300w pure sine inverter to use for AC and put its pieces inside and etc. after some reconfiguring. Also got the DC outlets and etc. in. I have to pick up a 40a DC relay which will switch all power on and figure out how I will mount the display, and then connect all the wires inside.. but this is how it is shaping up in a 50MM ammo case.

It will be charged with a portable 100W solar panel, or via a cigarette lighter when car is running. I am trying to source a small DC power supply that will fit inside also and will charge via 110vac.

Image

Image


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Don (Flboy)

YouTube Video of Finished 6x12 Trailer:
https://youtu.be/6_-8cVdWUIA
YouTube Video of 7*18 with 2ft V-nose Trailer:
https://youtu.be/MUcMM86LA2g
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Re: Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Postby flboy » Mon Apr 19, 2021 8:42 pm

Figured out the display, but may have a problem connecting the USB cable to it. Worse case, I buy another box and take the lid off. I have another battery monitor that may be easier to mount and connect, just not as detailed.

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Don (Flboy)

YouTube Video of Finished 6x12 Trailer:
https://youtu.be/6_-8cVdWUIA
YouTube Video of 7*18 with 2ft V-nose Trailer:
https://youtu.be/MUcMM86LA2g
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Re: Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Postby hankaye » Tue Apr 20, 2021 7:59 am

flboy, Howdy;

:applause: That is some very neat stuff, there. :thumbsup: :thumbsup:

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Re: Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Postby flboy » Tue Apr 20, 2021 8:54 am

Thanks Hank.

I did get the meter USB connected. Had a bit of a dilemma in fit, so I cut another piece out of the Bestek inverter case.

Image

Image

Used some stickers I was saving. Had to put the Yeti on there. Lol.

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Last edited by flboy on Tue Apr 20, 2021 12:09 pm, edited 3 times in total.
Don (Flboy)

YouTube Video of Finished 6x12 Trailer:
https://youtu.be/6_-8cVdWUIA
YouTube Video of 7*18 with 2ft V-nose Trailer:
https://youtu.be/MUcMM86LA2g
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flboy
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Re: Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Postby flboy » Tue Apr 20, 2021 10:22 am

Found a 15V 10A project power supply on AliExpress for $13.50 shipped. I think it will fit in the remaining space in the ammo can. If it does, I will be able to quick charge from 0Ah to 25aH in roughly 2.5 hrs. That would be nice. The PS has an adjustment that will adjust +/- 15%, so I should be able to dial it in at 14.6VDC which is perfect for LiFePo4 charger. The BMS will handle the charging parameters and shut off when tank is full.

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Don (Flboy)

YouTube Video of Finished 6x12 Trailer:
https://youtu.be/6_-8cVdWUIA
YouTube Video of 7*18 with 2ft V-nose Trailer:
https://youtu.be/MUcMM86LA2g
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flboy
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Re: Flboy - Custom 6x12 Off-Road Toy Hauler Conversion

Postby flboy » Tue Apr 20, 2021 3:16 pm

Added external fuses for outlets and soldered all the wires. Just need to get the power on relay and the correct BMS from China and this will be a wrap. I did test the Inverter and it still works well. I had to dismantle it quite a bit and reconfigure wiring.

Long story on the BMS, but they are sending me a free replacement... should be here next week.

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Sent from my SM-N970U using Tapatalk
Don (Flboy)

YouTube Video of Finished 6x12 Trailer:
https://youtu.be/6_-8cVdWUIA
YouTube Video of 7*18 with 2ft V-nose Trailer:
https://youtu.be/MUcMM86LA2g
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flboy
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