[Waverley ARS] Anderson Powerpole Distribution Box

[Henrik Stenstrom]

Here's a small project that should only take an evening or possibly two
to put together.  

Inspiration for this came after the recent John Moyle field day.  One of
the benefits of a day in the field is the possibility to see how others
set up their portable stations, in essence to see what works and what
doesn't.  I was particularly impressed with a small 12V distribution box
in Laurie-VK2JAH's portable kit.  Checking a few websites for price and
postage was all the extra motivation I needed to put a few of these
together.

The bill of materials is quite modest; you may well find all you need in
your magic box at home.  I sourced my parts from Altronics only because
I was placing an order for other bits and pieces at the same time. Cost
was about $6 not including the Anderson Power Pole connectors.

UB5 Jiffy Box - H0205
Automotive Style Fuse 25A - S5910
Blade Fuse Holder - S6040
Switch - S3247

Additionally:
Anderson Power Pole Connector Sets x 7
Solid Copper Wire 1.5mm x 30cm approx
Single Sided Circuit Board 40 x 75mm
15mm M3 standoff x 1
M3 screws x 2

Construction is simple if you follow the adage of measure 20 times and
cut once.

The Anderson Power Pole contacts are crimped and soldered to 20mm
lengths of 1.5mm solid copper wire.  I used pieces of hard drawn copper
antenna wire leftovers.

The circuit board is drilled 1.5mm to accept the Power Pole sets, 3mm
for the standoff and slotted at one end to accept the blade contacts of
the rocker switch.

Use the circuit board as a template to nibble out clearance holes in the
bottom of the Jiffy Box for Power Pole sets, Fuse and Switch.  Install
the switch (press fit) in the bottom of the Jiffy Box.

The Power Pole Sets and Fuse Holder are then soldered into place on the
circuit board.  Use a Dremel tool with cutoff wheel to engrave the
copper side of the circuit board to produce "tracks" as required. In the
arrangement I've used there is one input; all outputs are fused with
three being permanently on and the other three switchable.

The completed circuit board is then installed upside down in the Jiffy
Box from the top with one end supported directly upon the switch blade
contacts and soldered in place.  The other end of the circuit board is
supported on the 15mm standoff.  The Jiffy Box lid forms the base of the
box.

There you have it and I hope the pictures to follow are worth their
respective 1000 words.

VK2HHS - Henrik