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Building a custom DIY Powerwall Enclosure

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Today, i'm going to show you how to turn 20 of these scooters into a big power wall all right. So how do we go from the scooter to the power wall? Well, you see each one of these scooters has batteries inside this is a battery and then inside this tube there's another battery and there's all kinds of different uh versions. Right, there's another one here. This is a 30 cell from another uh model of these, and all of these are scooter batteries, so we're gon na turn one particular model of these into a powerwall.

So, let's start step one you got ta install an enclosure for your diy powerwall metal enclosures are typically really expensive, and so what i ended up doing here was making my own, and i made a whole video showing you exactly how to make this. You can actually get all these pieces already pre-cut and i show in the video how to just put together. You do need a few tools, like maybe a drill with drill bits. You know and a rivet uh maker.

You know, and maybe a chop saw to cut some of the aluminum angles that you put in here, but i will link that video on how to make this custom aluminum powerwall box in the description of this video. So for now step one and this video is to install it the holes on this box. Mark the holes, your mind, step two. You got ta install the megalodon, that's what we're calling it here in-house.

This is basically the same product that we have as a single double triple and quadruple, but this one is much bigger. You can put up to 10 of these batteries the scooter batteries and it will handle all the logic that it needs so that you can charge them and discharge them safely and those other stuff right. So we have two versions of them. We have the master board and then we have the uh slave boards, the master one.

The only difference between the masternode is that the master has a meter built in here, and it's got a current sensor and stuff, and so it will keep track of all the energy that goes into your battery and out of your battery. So this is going to be the way that you tell what what your battery is doing and the state of charge and all this other stuff right and so then the master one has that and then you could add slave boards to that. So, in this case, we're gon na make a pack that is gon na use 20 of these scooter batteries right. So we need two of them right and so, in order to add a second one, we made this little board right here.

That will just bridges one to the other one that connects the three main connectors and you can do that on the bottom and you can do that on the top. So you can just add more slave boards to your master board. And so, if you want to build like a bigger battery, then you can keep doing that in this case, we're going to use two of those for 20 packs. So the thing that you have to do is you just have to drill holes like we did here on the side of your enclosure and then you just screw them from the inside we're using these standoffs that are made out of plastic so that that keeps it Isolated from the metallic uh surface of this enclosure and then that way, you'll keep it nice and isolated, so it doesn't show up so we're gon na install this mega dongle into the battery line it up and four screws.

This thing is over here: let's install the inverter now the rain positive, so next step is to install the batteries. So these batteries are super super safe. They have a active bms inside and when we're installing them in here we're using that bms. Also, these are encased in rubberized compound that is anti it's a fire retardant and also a thermal compound so that the batteries can get rid of any heat that they can develop.

Also they're inside of this very, very tough weather seal aluminum casing right. So when you're putting inside this box right here, you're double boxing them, so these are super safe. Even if one of these ever catches fire well, first it has to go through the rubber. Then it has to go through his own weather seal aluminum casing, and then it has to go through this other aluminum casing right so uh i think uh.

These are some of the safest batteries that you can possibly put in your wall and they're super easy to install because look. This is all how you connect them: the small cable and then the big cable. Just do the thing. Okay, now here's the thing while you're connecting these it's going to try to fill the since we already have connected the inverter is gon na try to fill the caps in the inverter, but a single battery won't be able to do that, so it might turn on.

Just momentarily and it'll turn off right because it's it it exceeds the amount of power that a single one can do so eventually, as you keep connecting them, maybe the whole system will energize, but maybe not, and that's, okay, because at the very end you'll just connect. The charger and then all of these will wake up and then it'll charge the caps in the inverter and then you'll be ready to go. So that's the procedure connect all of the batteries next, your sensor, so it's a single one, there's 20 packs in here. So you just pick one and then you put it in there, i'm gon na put it on the very top because heat rises, so this gets really hot inside here.

Then this will pick it up and if the batteries get hot, then um one. Even one of these ones well it'll generate heat and it'll. This is going to be kind of like a general temperature right and you'll be able to read this on the meter itself, so there you go just put it on there all right. So here it is.

It's that simple, you basically install the boxes on the wall. Then you install your charger, you install your inverter and then you connect all your batteries and then, if the batteries are on right, then you're good to go. I mean if they're not, then you just plug in the charger and then they'll turn themselves on and it'll be fine right. So, let's run a little bit from others.

These things are super super safe because each one is fused and internally and then externally - and they have a temperature sensor in here and they have two circuits a charging circuit and i have this charging circuit and they are active battery management system. So these are about the safest batteries that you can get so here it is. This is about 10 kilowatt hours, and now, let's talk about the chargers, the charger is a 36 volt charger, and here is one that we've used before and it's uh super reliable. It's kind of inexpensive um, it's a good charger.

Okay. So in this particular project i didn't end up using that charger right and the reason is because i'm trying to cut costs even further - that's a great charger. It's really affordable. You can find it online it'll be linked on the bottom, but here's what i use i ended up using the actual chargers that i use to charge: scooters uh.

These are available in large quantities and we were able to source them really really cheap, and so i built this - and this might be way cheaper than that, but i still have to work out some kinks and some bugs in this thing. So it's not available. As of yet, but if you're watching this video in the future, then it might be available right. So, let's move on to the meter.

The meter here is included in the master version of the mega, lo dongle right or the big dongle that we have here and so uh. There will likely need to be some uh setup for this meter so that you can, you know, tune it, and you know, do you know sync it so that it works? I will have to make another video and i will go into very fine detail on what i had to do to get this running. So it works perfect with this setup, keep an eye open for that right. So here's the other thing uh.

We have to work really hard to get these products. You know develop, there's a lot of testing, there's a lot of trial and error, and so by the time that we're making this video these batteries now are unlimited basis right, there's not a ton of them left, and so, if you're watching this in the future. Well, you might find out that these are sold out. If that happens, and don't worry, because there are a ton and a ton of different versions of these scooter batteries and yeah.

I will try to keep the links on this video up to date. So just click on the links and hopefully you'll be able to find them right. This is just my warehouse, it's full of these batteries, but by no means i'm the only source in the united states. So there are a ton of people that are making this available.

Uh, you know i might be the best one to get them, because i'll do i will be able to vet the bad ones from the good ones and we'll try to you know, do the thing, but definitely keep your eyes open. There are a lot of places and a lot of ways to find really good deals on these batteries. It's never been better to buy batteries. They're they're never going to be more expensive than now they're, just going to keep going down price.

So next is the inverter. Let's talk about the inverter, the inverter are, this is just a regular 36 volt inverter right and there are plenty of them in the market. This just happens to be a really affordable one and it's great for the occasional use. If you're gon na use this setup right here, just as a backup right so for the occasional use when the power goes down, this is gon na, be great.

It's gon na work for you now. If you're gon na use your battery every day and you're gon na give it heavy use, probably not the best, it's not gon na last, very long right, just that's just the nature of things they don't last forever. You buy something affordable, it's not gon na say, but not to worry, because there are plenty on the market. If you want something more robust and more reliable, you can find something that is better quality.

The last thing to do now is just to test it. We're going gon na turn all the circuit breakers off and that's gon na simulate a power outage and then we're gon na turn. This right here, which this is a transfer, switch right. Every building every house should have this.

Unfortunately, they don't, but you could have one of these installed and this is allows you to very quickly uh, be able to connect a generator right, that's what they were designed for generator, but it doesn't matter if you put an inverter right, it doesn't care where the Power is coming, but it allows you to very easily isolate the the circuits that are uh more important to you, and so you know at the critical loads you'd be able to put them through here and do that. So that's what we're going to do. Let's turn all the circuits off so now we turn on the inverter. Look at that there's a little light that comes on here and now we start turning on the the switches.

So that's one circuit, that's probably likely like the uh plugs or the lights out in front. I think these are the lights here on the. Where else look at that that thing turned itself off: okay, now even the plugs here on the warehouse there we go. That's something that had a load because they flickered and there we go so now.

We have all our critical loads running off of this inverter and it's not running much. Let's see, okay so in the custom cable that i made so that you can connect inverter to that. I also have a little meter, and so this one is going to show you. It has some analog uh meters here and it tells you you're running about 600 uh watts from that one leg right.

So this one actually look at that. It matches 641 watts 120, volts 500, uh, 5.3 8 amps of current right. So there we go we're just running a small load. Basically, the lights are here: there's not a lot happening on this warehouse right now, but if the power goes out and we need to come in here and we need to work no problem - you just flip those switches, you're up and running, so every house should be Like that, and if you want to get uh a backup power, this is the easiest way to do it.

The last thing is to put the cover on there. We go yummy.

14 thoughts on “10kwh DIY Powerwall project”
  1. Avataaar/Circle Created with python_avatars Miguel M says:

    @jehugarcia, that transfer switch has two legs. Did you put the white together and the blue wires together to make it one. Or you feeding two 120 on each leg or side from the inverter? I see two plus on the inverter. I ask cause I was going to do the same.

  2. Avataaar/Circle Created with python_avatars No Name says:

    hello, I really like to build a 48volt battery but I cant find all the parts I need on your website to complete a project. I just don't want to get stuck with parts I'll never use if the other components aren't available. thanks for your videos

  3. Avataaar/Circle Created with python_avatars 123karismith says:

    Jehu, you're sold out of the Master Megladongle… I don't want to order a slave and batteries unless you are going to build more Masters. Can you confirm that more Masters are being built and is there a way to reserve one? If yes, I'll order 20 scooter batteries and the slave dongle now. Please let us know if more are in the mix, thx

  4. Avataaar/Circle Created with python_avatars Richard Eun says:

    Can you extract the cells out of this battery pack? I watched your other video where you harvested cells from a scooter pack, but when I clicked on the link to purchase them, they are sold out or no longer there. Can you please help me find 18650 cells to buy economically?

  5. Avataaar/Circle Created with python_avatars Michael Hammons says:

    How do you feel knowing that people watch your videos and go out start stealing scooters. I've talked over 100 people who I've caught with stolen scooters they got the idea from your videos. Theft of scooters are getting higher and higher because of the stuff you share.

  6. Avataaar/Circle Created with python_avatars brian olson says:

    A listing of parts and where to purchase them would be helpful. The battery enclosure can be purchased as a electrical panel can, just need the dimensions.

  7. Avataaar/Circle Created with python_avatars Andras Ivacson says:

    Every house shouldn’t be like that. The power network should be made more resilient and avoid outages. Placing such capacities of batteries in every house is insanely irresponsible.
    Think about the ecological impact before piling up that amount of batteries in your warehouse just for fun.

  8. Avataaar/Circle Created with python_avatars Robert Davis Daily says:

    Probably not a big deal but to be able to get into and tinker, change things etc, adding thumb screws from a pc. I can also say that you could totally hook this up to solar/wind. How many hours do you get with this setup?

  9. Avataaar/Circle Created with python_avatars Ric Desan says:

    Picking packs 9 through 20 in about a week (last in stock near me and cheap.) Managed to hit the $100 per kWh on the packs overall so the tough decision is not to harvest out and stick with the 36v environment OR go down the PCB 24v rabbit hole with cell level replacement and more inverter options …. you make it tough Jehu!!!

  10. Avataaar/Circle Created with python_avatars Lennie Beckford says:

    Hi Jehu. Great video as always. Thanks. Would it be possible to make a video on a custom metal cabinet for 48 or 64 Eve/Lishen 3.2v cells with locking wheel casters and door. That would be cool. Alternatively any alteration of an existing metal cabinet that would neatly hold 64 of said cells. 🇬🇧🇯🇲

  11. Avataaar/Circle Created with python_avatars Dimrain13 says:

    Ahhh Thats perfect! I would double like this if I could. Seems a bit steep on the pricing though if I could afford that I would go that route instead of the DIY wake up for the batteries. I have 40 battery packs and to pay $1100 to enable the batteries that cost $2200 seems fair when you consider the total price per watt, but when I already paid $182 for basically the same setup without the wake up module installed its hard to understand the price. If the price for 4 was around half that price I would start from scratch and buy them, but maybe theres some more to it that the PCB powerstrips dont do?

  12. Avataaar/Circle Created with python_avatars Ecospider5 says:

    Heat does not rise. Hot air rises. So if you do not have good airflow each battery will radiate heat in all directions. Which means without airflow the center battery will be the hottest.

  13. Avataaar/Circle Created with python_avatars Daniel Eriksson says:

    2 questions. 1. Why is there no floor clearance? (cleaning and potential water leaks?). 2. What's the difference between Aluminium, and Aluminom? or are you just replacing the "iu" with an "o"?

  14. Avataaar/Circle Created with python_avatars Mike B. Pyro says:

    In some states the power companies will give you discounted power rates in off peak hours. This is a set up that could pay for itself by charging the batteries in the off peak hours then in peak you remove yourself from the grid and use the power you saved from the night before and you are helping keep the power grid more stable.

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