Portable Solar Station Build - Relaxing DIY Woodworking in the Garage

I am a woodworker, but I'm also a nerd who loves gadgets. I camp a lot, and I wanted a way to charge my drone, camera, and laptop while I'm in the middle of nowhere.

Sure, you can buy a Jackery or an EcoFlow, but where is the fun in that? Also, they are expensive! I decided to build my own "Solar Generator" using a deep cycle battery and some components I bought online, and of course, I built a custom wooden case for it.

Disclaimer: I am not an electrician. This project involves high-current 12V DC and 120V AC electricity. Proceed at your own risk and do your research on wire sizing and fusing!

The Concept: What goes in the box?

A solar generator is basically three things:

The Tank: A Dictionary-sized battery (LiFePO4 is best, but I used AGM Lead Acid because it's cheap).
The Filler: A Solar Charge Controller (MPPT) that takes raw energy from solar panels and safely puts it into the battery.
The Spigot: An Inverter (changes 12V DC to 120V AC wall power) and USB outlets.

My goal was to package all of these into a compact, rugged plywood box that I could throw in the back of my truck.

Material & Tools

Electronics

100Ah AGM Battery: Heavy (60lbs), but reliable.
Renogy Wanderer Charge Controller: Simple, effective.
1000W Pure Sine Wave Inverter: "Pure Sine" is important for sensitive electronics like laptops.
12V Fuse Block: Safety first! Fuses prevent fires.
Heavy Gauge Wire: 4AWG for the battery and inverter connections.

The Box Materials

1/2" Baltic Birch Plywood: Extremely strong and holds screws well.
Box Joint Jig: I wanted strong corners because this box is heavy.
Handle: A heavy-duty chest handle.

The Build Process

Step 1: Component Layout (Tetris)

Before cutting wood, I laid all the electronic parts on my bench. I realized the battery is huge. I had to arrange the inverter and charge controller around it to minimize the footprint. I left 2 inches of air gap for cooling fans. Inverters get HOT.

Step 2: Joinery (Box Joints)

I used a box joint jig on my table saw.

Why Box Joints?: They provide a massive amount of glue surface area. For a heavy load like a lead-acid battery, simple butt joints might fail if you drop the box. Box joints interlock like fingers.
The Cut: I cut the fingers on all four sides. The fit was tight—I had to use a mallet to tap them together.

Step 3: Cutouts

This was the tedious part. I had to cut specific holes for:

The Inverter faceplate.
The Charge Controller screen.
The USB ports.
Cooling fans (Intake and Exhaust). I used a jigsaw and a rasp to file the holes to the perfect size.

Step 4: Assembly & Finish

I glued up the box. Once dry, I sanded everything smooth and applied Boiled Linseed Oil. It protects the wood but keeps that natural, rugged look. It smells like a workshop, which is a bonus.

Step 5: Wiring (The Scary Part)

I wired everything up.

Positive to Positive.
Negative to Negative.
Fuses: I put a master fuse right at the battery terminal.
Switch: I added a master disconnect switch so the battery doesn't drain when not in use.

Pro Tips / "Don't Do What I Did"

Mistake #1: Weight Distribution: I put the handle in the center of the lid. But the battery is on one side. When I picked it up, the box tilted aggressively and hit my shin. Find the center of gravity BEFORE mounting the handle.
Mistake #2: Wire Crimping: I tried to crimp 4AWG wire with pliers. It didn't hold. I had to buy a proper hydraulic crimper ($40 on Amazon). Loose connections cause heat and fires.
Tip: Use Anderson Powerpole connectors for the solar input. They are universal and safe.

Conclusion

This box has traveled hundreds of miles with me. It runs my camp lights, charges my drone batteries 50 times over, and even runs a small blender for margaritas (essential survival gear).

It weighs 75lbs, so it's not "backpacking portable," but for car camping, it is a beast. Plus, I learned a ton about electricity relative to woodworking.

[!NOTE] Battery Upgrade: If I did this again, I would use LiFePO4 (Lithium Iron Phosphate) batteries. They are half the weight and provide twice the usable power, though they cost 3x as much.