back to mark 2 combiners

02 panel combiner assembly:


And here's step-by-step pictures of the construction process for the panel combiners. After the laborious
process of cutting the holes cut in the boxes, I start by scuffing up the plastic inside the case around the
powerpole and meter holes. I've found that (especially with the powerpoles) the hot glue can "pop" off smooth
plastic surfaces. Scuffing seems to prevent that, even with the sometimes rough handling on the powerpoles.

I cleaned up with 100% alcohol and a q-tip before proceeding, and was surprised by the amount of debris and
fine plastic dust I got up, so don't skip this step. Then the box was set down on a flat table and the meters
were dropped in and glued along one edge while they sat flush with the front of the box. (which is actually
the bottom) Next I used another box and heavy wire as a guide to hold the powerpoles in placed as I glued
them along the top on the inside. After all that was cool, I added more glue around the inside and also
carefully applied glue around the outside perimeter for waterproofing. Having glue on the inside and the
outside provides good suport for both powerpole connect and disconnect.

Although the pictures show the meter wires on, I ended up removing them from the meters and soldering them
up with the powerpoles, splices, and fuse. I used a smaller 15mm fuse and compact holder due to limited room
inside the box. After the wiring was soldered, I carefully soldered the meter wires back down. (this was
mainly a precaution against wire fatigue causing the wires to break away from the meter during soldering
with the heavier wires and parts) Finally, the powerpoles were pushed into place and the wires and fuse were
tucked away prior to buttoning it up.

As it is now, the inside path on the powerpoles isn't waterproof, (nor is the mating surface between the two
housings I suppose) and the meters aren't waterproofed. But I intend to cover the top with lightly smoked
clear plexi sheet to cut down on the glare, so the meters don't worry me. I could add glue in or around the
powerpole connector on the inside of the enclosure, but I don't think the inner connector is a big issue
once the panels are plugged in.

02 assembling powerpole hardware	03 scuffing plastic for hot glue	04 used a file for deep scuffing	05 powerpoles also scuffed inside	06 alcohol cleanup after scuffing	07 inside glued
08 positioning powerpoles for gluing	09 inside hot glue on powerpoles and meters	10 meters were flush-mounted	11 wiring prepared	12 wiring solderd to meters	13 contacts inserted and wires dressed
14 closed before gluing external ports	15 hot glue on outside for waterproofing	16 assembled

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