DIY Ryobi 18V One+ Powerstation

I have a bunch of different Ryobi 18V Power tools and an assortment of One+ Lithium batteries. I thought it would be great to make use of these batteries for other things. I decided to make a Power station that could charge USB devices and run 12V cigarette lighter socket devices. I also added an LED light for emergencies. It has room for 3 different sockets. I currently use one that has two 2.4A USB connections, another that has a QC 3.0 and Type C connectors, and a third that is a 12V cigarette light socket.

This can easily charge your cell phone or run a laptop
You could use the 12V socket to run a small AC inverter or a CPAP machine when you are camping or traveling

Here is a movie of the build process: https://youtu.be/p9G_shkDBt4
An earlier prototype can be viewed at: https://youtu.be/rdvFLKf1roE

I just tested all my Ryobi tool batteries for capacity. I used a load tester ( https://amzn.to/2SOyXcg ) running at 10A/12V regulated load ( https://amzn.to/2SGAoei ):

• Ryobi 9Ah/162Wh P194 got 133Wh
• Ryobi 6Ah/108Wh P193 got 98Wh
• Vanon 6Ah / 108Wh got ONLY 58 Wh
• Ryobi 4Ah/74 Wh P108 got 55Wh
• Ryobi 3Ah/54 Wh P191 got 42Wh
• Ryobi 1.5Ah/28 Wh P107 got 19Wh
• Ryobi ?Ah/24 Wh P102 got 13Wh

Here is the parts list:
 

• Ryobi 18V 9Ah Lithium battery ( https://amzn.to/38oLFFm )
• Bestek 300Watt Pure Sine wave AC inverter ( https://amzn.to/37kdnBQ )
• Ryobi 150-Watt Powered Inverter, with 2 USB Ports and One 120-Volt Outlet ( https://amzn.to/2Shahu1 )
• Ryobi 18V One+ Dual Chemistry Vehicle charger ( https://amzn.to/2vouV2n )
• DC-DC 10A 12V buck converter ( https://amzn.to/2SjwSGn )
• cigarette lighter socket ( https://amzn.to/3byDuYX )
• dual 2.4A USB ports ( https://amzn.to/31MaZ5x )
• QC 3.0 and type C socket ( https://amzn.to/3buZkwz )
• toggle switch ( https://amzn.to/2uGV8ZU )
• LED puck light ( https://amzn.to/2vmlSz8 )
• Battery Leaf springs ( https://amzn.to/31KSCy5 )
• 2.85mm ABS Filament 1kg for 3D Printers, Fluorescent Green ( https://amzn.to/38B0W6f )
• Flexible 12 AWG Stranded Copper Wire ( https://amzn.to/38Ni1JW )
• 3/4" strap / Heavyweight Polypropylene Webbing ( https://amzn.to/39Lom93 )

As an Amazon Associate I earn from qualifying purchases.

Hackaday just picked up on this project and wrote an article! ( https://hackaday.com/2020/02/20/diy-power-station-puts-ryobi-batteries-to-work/ )

I went thru several prototypes making improvements on each one. That's the beauty of 3D printing. Quick turn-around to try new things!

Revision History (see photo):
prototype -- tested battery connection
prototype V1 -- functional test of DC-DC converter, USB ports / 12V cigarette socket
prototype V2 - New tower shape with 3 socket holes
prototype V2a - added handle strap
prototype V2b - added second switch to turn all power off, thickened strap holder
prototype V2c - lengthened DC converter opening, beveled edges, widened strap holder opening
future improvements: label switches with icons, put switch notches in model

I put the 3D geometry model on thingiverse to make it easier to adapt: https://www.thingiverse.com/thing:4168822
(Didn't know how to load STEP file here :-( )
You can try loading it from: http://howmuchsnow.com/batterypowersystem/ryobipowerstationV3c.stp

Print instructions

I don't have a 3D printer, so I borrowed time on my friends Airwolf printer. The prototypes were printed with ABS on a heated platform in a heated chamber. The nozzle size was 0.5mm and the build strength was strong.

Make sure you orient the model so that the strap holders are down on the printer bed.

I used a wood file to put notches in the switch holes for the clips and for the switch tab that clocks the switch. Other switches may not require this. I also add hot glue to the back of the switches once installed.

After inserting the battery spring clips and getting them aligned / tested, I use hot glue to secure/insulate them