A few days ago, I began working on a new project, regenerating a Civic's Hybrid batteries that are completely dead and the car will no longer recognize the cells. In the middle of the process, I had a brain blast and decided to start another project that reminds me of the olden days of computer modding and water cooling. Granted there will be no water cooling needed for this project, im still super hyped for it.

For the longest time, I've had this Nike box sitting around that a pair of Air Jordans once came in. Its a very nice carry case and I hate the thought of throwing it out since the shoes are long gone. This gave me a good idea to re-purpose it and give it a new life.



I keep a healthy supply of replacement fans and other "computer" related hardware on hand because that's what I do.. I will try to break this down as I go to give you guys an idea of what's going on and provide plenty of pics for visual effect.

First of all, the box will house a total of five gutted TC-1030 chargers. I will add more on that later. This many chargers confined in one box plus the high amp power supply will create a good bit of heat. Cooling is a necessity.

The first thing I decided to tackle is the cross air flow with four 60mm fans that will pull the warm air out the end at the same time injecting fresh cool air in at the other end. Here are some pics to show my thought's so far;




Thus far, ive gotten the fans mounted with the fans guards. The next step will be to cut out the openings and this is where im at a cross road. I'm debating weather to cut out the small space in between the fans or leave it be and only cut out the holes..



Here is what the fans look like inside lined up and mounted. I plan to use the fans to exhaust the warm air from that end of the case. All four fans run at 12v and .44amps current draw. This power will be supplied by the main PSU that will rest at the bottom of the case supplying 12v, 60+ amps at 700+ watts. When this project progresses, the inside will be painted satin black. The "yellowish" color is a primer.




At this point, I have three TC-1030's out of the total five that I need. I was in talks with another user who had two but he never returned my PM's after telling me that they are still available. Lastly, I am in need of a friend in the NE Ohio region who has access to a CNC router. The cover panel will be made from acrylic and needs to be machined. I am in the middle of creating the design in SketchUp and I will post some images shortly.

Any ideas, feel free to chime in. A large amount of switches, plugs and buttons have been ordered on eBay. Here's is an idea of what's to come;

*Voltage and Amperage meters for each of the five channels.
*Individual power switches to each channel.
*Fan controller for the four cooling fans.
*Upgraded aluminum heat sink for the discharge MOSFETS.
*External modular power plug with main power switch/fuse.

Another small update. I am planning on using a very slim but powerful PSU to power everything pictured below. It is one of the thinnest PSU's ive used to date pushing 60+ amps!





Also, while digging through a bog of parts I came across a goodie that will work perfect. Its a panel mount three prong plug that can handle over 20 amps AC! It will work perfect as the main power connection. I drew up a template of where it will be. Now I just need to find a 1" hole maker... Finding a drill bit that big will be a challenge I don't care to attempt and the biggest stepping drill bit I have is 7/8"... FML

Found this fine tooth, 1" hole saw at lowes made by DeWalt. Its awesome!



Cut the hole like a hot knife through butter and very clean cut too.





Installed the plug using some left over m3 screws, washers and lock nuts. I do have some silver stainless steel screws on the way however.





Last but not least, is the beefy power plug, this thing is official!



Im slowely receiving switches and encoders piece by piece. I did find someone local who will help me with the CNC needs. That's a huge weight off my shoulders too. Also thinking about praying the entire outside of the case with truck bed rhino lining that's sold in spray cans. Should be an interesting look. I will update more as it comes!