I got a Radio Shack PowerUp 12v/12ah car starter on close-out for $19.95. Chris K6DBG ordered a couple of PowerPole chassis mounts (HS-8) from PowerWerx and I fit mine into the case.

1. First I removed the heavy, unfused battery clamps and set them aside, probably to re-use the wire for something else.
2. Next, I used double spade lug connectors from West Marine to hook the plus and minus leads from the PowerPoles together and to the plus side of the battery breaker and the minus side of the battery and its charger (which I had to cut and crimp again).
3. I routed the negative leads through the upper part of the handle area, to keep them away from the charger heat sink, but when I put it together, it still got a bit close.
4. I covered all exposed + leads (battery, circuit breaker) with electrical tape, to protect them during reassembly. I also put a strip on the back of the charger circuit board as the negative wires ran a little close; something harder would be better.
5. I cut a small amount of plastic from the thin vanes on the case so that the PowerPole chassis mount would fit. This unfortunately left some holes around the square area where the lighter hack was. I covered these with electrical tape for now.

Here is the connector I made, the inside without the connector, the installation location, and the finished view from the side:

Gotchas:

• The plus lead from the charger to the battery pulled off the charger board, giving me a few anxious moments until I noticed that there was a solder pad with wire impressions still in it, so I found out where it went.
• I unnecessarily cut the yellow wire on the transformer, because I didn't know that it popped right out.
• If I had it to do again, I would make the negative leads on the connector shorter to keep them further away from the charger voltage regulator heat sink.

Next steps:

• Make a plastic frame to cover the remaining holes around the powerpoles.
• Check to make sure that the negative wires aren't getting too warm and close to the charger voltage regulator heat sink.
• Saw the plastic posts off the back.

- posted by Leigh @ 21:57 z