DIY Ham Radio Project - Inline Power Guard - Circuit Protection
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About this video
A Fun, Educational, Ham Radio Project!
Parts Used:
Power Pole Connectors
amzn.to/3yoMzne
12 AWG Wire for 25 Amp
Fuses/Circuit Breakers
Ring Connectors
Alternatives to this project: Inline Fuses - amzn.to/3WFDnVD
or
Inline Circuit Breakers mentioned in the video (not tested, available in 10a,15a,20a,30a etc): amzn.to/4dGfvHt
(All links are Amazon affiliate links. I may make a commission off the sale. If you can find them cheaper elsewhere, go for it. If not, thanks for your support!)
STL File:
Download the STL File on Thingiverse
thingiverse.com/thing:6619508
Why This Box?
How many times have you been in the field and your fuses tripped, but you didn't have any other fuses to replace them? For me, never... So, solutions to problems that don't exist—we call that preventative! 😄
Knowledge was the reason for this box.
Printing Details:
Material: ASA (I did print these with PLA, they will hold up fine for standard use. Maybe don't leave the print in a hot car though)
Infill: 25%
Assembly: Box can be screwed together, but there's a nice fit without screws. Additionally, you could add some threaded adapters to them like seen here - amzn.to/3ywhP3w
This was mainly an opportunity to learn a few things about Fusion 360.
Learning Opportunities for Ham Radio Enthusiasts:
3D Printing, obviously.
Crimping Powerpoles
(I know a guy with a good video: youtube.com/watch?v=fLjaKC3X7WY)
How to Crimp Ring Connectors
Choosing the Right Wire Gauge for circuit breakers, fuses, etc.
Implementing in Your Projects: Many times, we forget the joy of the makerspace is making it ours, and coming up with unique ideas.
Future Plans:
Positive Side Only Version: This will feature one inline breaker and direct negative wiring between each power pole, greatly reducing cost.
Inline Reverse Polarity Protection?
Labeling: Add "AUX" and "BAT" text on the top of the plate to prevent incorrect installation.
Marine Grade Ring Connectors: Get #10 connectors.
Improved Power Pole Connector Inserts: Currently, they do okay, but it would be best if glued in, which I'd like to avoid. My ultimate goal is to make them click in and stay in somehow.
Safety Enhancements: Maybe add a wall between both circuit breakers to prevent accidents and protect your equipment.
Final Thoughts:
After recording this video, I discovered a possible reason companies like Yaesu double fuse. The potential explanation is here: amateurradio.com/mobile-dc-power-one-fuse-… (Thanks for the write up K0NR, Bob)
I had a really good time building this box, ham radio dudes box... the most interesting box in the world. Remember, make ham radio yours and enjoy whatever you make it; a sport, hobby, or service... Enough rambling, have a good one; enjoy!
