This video is my step-by-step guide to building a portable solar “generator” for camping, basic off-grid living, etc. It’s basically a self-contained ammo can-style setup (i.e., a lot of people build something like this using an ammo can/box), but my batteries are larger than what I could fit into an ammo can, so I had to upgrade to a larger box. I use it to power my laptop, charge camera batteries, run a fan, and charge my phone and tablet. (Click here if you can’t see the video below.)
The video is the main thing, but the information below the video here is supplemental to help you out.
BEFORE WE START
I am not an electrician. I basically have no idea what I’m doing, but I was able to successfully build a solar setup that works well so far. Follow these instructions at your own risk. You’re on your own here. Don’t blame me if you mess something up, break something, or hurt someone.
This is the diagram/schematic that I followed (click it for larger version). I recommend printing it out:
And then this is the battery charge percentage chart that I reference in the video.
COMPONENTS
These are the components I used, and I’ve included links to the products on Amazon or Walmart.com as appropriate. (Note that most of these are Amazon affiliate links, and I’ll get a small commission if you buy them or something else from Amazon through the links.)
- 100-watt solar panel
- 2 35Ah batteries
- Mighty Max Battery 12V 35Ah DC Deep Cycle SLA Battery ($64 each; $128 total)
- 400 watt inverter
- Solar charge controller
- Fuse holders
- E Support 12 Gauge ATC In-Line Fuse Holder ($8 for a 5-pack, but I used only 2 of them)
- Wired 12-volt socket
- Plastic box
- Hefty HI-RISE Heavy Duty Storage Bins, 18 Qt. ($6 @ Walmart)
- Solar cables
- Box of assorted cable connectors
- Hyper Tough Assorted Connects ($4 @ Walmart)
- 2 7.5-amp fuses
- Cables for wiring batteries in parallel
- Machine screws
- 8 of them; #6 – 32 x 3/4″ ($2 @ Home Depot)
****TOTAL: $390*****
TOOLS USED
- Drill
- Drill bits (I used the 7/64″ one to drill holes for the machine screws)
- Spade bits (I used only the 1/2″ one)
- Pliers
- Tape measure
- Screwdriver
- Small screwdiver
- Utility knife
- Wire stripper/crimper – I bought this one from Walmart, which is also currently on Amazon.
STEPS
I won’t go into a TON of detail here because I do that in the above video. But just as a reference point, here are the steps I went through to create my portable solar setup:
1. Gather materials.
2. Cover solar panel with towel.
3. Mount charge controller.
4. Cut a bit of the plastic off of the lip of the side of the box.
5. Mount the inverter.
6. Cut the 15′ solar cables down to size (10 ft).
7. Cut a ~13″ piece of the black cable from the 5-foot piece just cut off.
8. Strip the ends of the 13″ black piece and one of the red fuse holders.
9. Add a ring terminal to one end of the 13″ black piece and the red fuse holder.
10. Drill a wire passthrough hole just below the charge controller.
11. Plug one end of the 13″ black piece into its respective terminal/socket on the bottom side of the charge controller.
12. Attach the other end of the 13″ black piece (the end with the ring terminal) to the negative side of the battery.
13. Repeat steps 11 and 12 with the red fuse holder.
14. Cut off another ~13″ from the end of the red solar cable and strip the end of the remaining solar cable.
15. Strip both ends of another one of the red fuse holders and strip the end of the long black solar cable.
16. Use a butt connector to join the red solar cable and the red fuse holder.
17. Connect the stripped ends of the long solar cables to their respective terminals on the underside of the charge controller.
18. Plug the long solar cables into the solar panel.
19. Attach the 12-volt cigarette lighter plug socket thing to the battery terminals.
20. Attach the inverter cables to the inverter after drilling a hole for the cables to go through.
21. Connect the inverter to the battery by plugging the inverter’s cable into the 12-volt socket .
22. Uncover the solar panel.
23. Test everything to make sure it works.