I have a thin Baseus 100W Power Bank that I want to mount into my bike's cargo basket. But it's a bit awkwardly shaped for mounting. Plus, I want to have a bit of rain protection, and hiding this expensive-looking bit of tech inside a plastic black box might help deter theft.
This case fully seals in the battery bank, with room for all four USB cables to come out of a small opening. If you want to still see the display, there is a variant with a cutout to glue a clear acrylic sheet in.
Parts Needed:
- Six (6) M3 screws (14-18mm length, you've got some wiggle room)
Optional Parts:
- Six (6) M3 hex nuts
- Thin (under 1mm, I use 0.4mm) acrylic sheet, cut to 47mm x 134.5mm
- CA Glue
- Silicone glue for weather sealing
Assembly:
- Use CA glue to glue the hex nuts in place. The screw holes are small enough that you can self-tap them in, but these nuts will let you open and close the box many times without stripping the plastic on bofa the box halves.
- Use CA glue to affix the acrylic panel in place. CA glue is pretty liquid, and you might not completely seal the panel with one pass. Wait for it to dry, and do another pass, or supplement with silicone glue.
- Attach all the USB cables you want connected to the battery bank.
- Fit the battery bank and button shaft into the base.
- If you want weather sealing, put a thin bit of silicone around the edges. You can put a tiny bit of silicone around part of the button shaft as well, since silicone has some flex to it, and you only need to indent the button a fraction of a millimeter to press the power button in.
Remember: Most FDM prints are not perfectly water tight. You can get better water resistance by using more outer layers, or by painting the print with a sealant. - Put the top on and screw it in place.
- For more weather sealing, squirt more silicone in the USB cable gaps.
Mounting:
It's a flat brick, so you have a number of options, depending on what you're trying to mount this to. Here are my suggestions:
- VHB Tape - The duct tape of 3D printing!
- Zip Tie Anchors - Print a few of these and use CA glue to affix them to the back of this case.
- Remix this model and add in screw holes.
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