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May 12, 2021, 07:20 PM
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Headway 38120 F5J charger build list and assembly


I really like the size, weight, and quality of this charging setup. I would call this a premium maker build considering the components and density of the design. Here is a finish shot. The deck was lightly sanded, primed, and painted with three coats of truck bed liner.

The case is a Progressiverc Sidekick or a Seahorse 300 - $49
https://www.progressiverc.com/produc...-sidekick-case
http://www.seahorsecases.com/Seahors...ping-Case.html

The battery cells are Headway 38120. The red high C cells are 8ah and the blue cells are lower C 10ah. I think the blue cells work just as well. Street price is anywhere between $14 and $25. Pricing actually has been coming down !!! I think I paid $169 delivered for 8.
https://www.amazon.com/Beautifur-Gen.../dp/B00Q2179ZU
https://batteryhookup.com/products/4...0a-super-cells
https://bmsbattery.com/battery-cell/...000mah32v.html

Toolkitrc M6D - $59
https://www.progressiverc.com/pages/...lts-page?q=m6d

Progressiverc 6S charging PCBs - $20
https://www.progressiverc.com/collec...34758344114311

30amp toggle marine breaker-$17
https://www.amazon.com/Blue-Sea-Syst...0868521&sr=8-3
https://www.westmarine.com/buy/blue-...8?recordNum=16

Morris 3 position DPDT switch 70111- $15
https://www.morrisproducts.com/pc_pr...D0E97A5436BE47
https://www.amazon.com/Morris-70111-...0868609&sr=8-2

Panel Mounted XT60

4mm banana terminals to charge internal batter or use as 12V out

For the battery bars 1.5MM X 15MM copper

4S battery extension to charge internal battery

4 1/4-20 button head screws

Misc 2.5mm hardware

Rustoleum truck bed liner
Last edited by Bmwjoon; Jun 10, 2021 at 01:29 PM.
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May 13, 2021, 09:10 AM
Registered User
Very Nice!!! Great work!
May 21, 2021, 08:22 AM
Barney Fife, Vigilante
tom43004's Avatar
Just ran across this thread.... NICE!

I have been concentrating on a F3K / F5K version of a charging box, also based on the HF cases.

I think mine is in version 11 or 12 now. It's amazing how much I keep tweaking, mostly to make them easier to build.
May 21, 2021, 03:13 PM
Registered User
Thread OP
The small HF case is perfect for small projects. I would like to try a dual channel charger, transformer type or laptop power supply and an internal battery next. Would be good for F5K.
May 21, 2021, 07:18 PM
Barney Fife, Vigilante
tom43004's Avatar
Hereís what I am working on... has a 24v power supply and space for a 4s lipo source or 12vdc through the DC in/out. Works for all of my small needs. Sorry I didnít have a pic of the finished product. I can take one tomorrow.

I may work on one with a larger box that can have its own internal DC source.
Jun 10, 2021, 01:35 PM
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I updated the post with the .STL files.

I've had a chance to test both battery chargers and both versions work great. I prefer the version with the LIFEPOE4 batteries. The source voltage vs. WH used feels very linear and the battery is very easy to charge. The SLA battery to me seems overrated. After about 120 WH used the voltage drops to 12V or so. I'm pretty sure it will still squeeze out another 50 WH but the voltage does sag to about 11.6 while using. No point in damaging the SLA. The LIFEPOE4 batteries can be discharged to 2.5V per cell and you don't feel like you are stealing any life from them if you need to charge a couple more batteries.

Cheers everyone and enjoy. If you have a little bit extra time and cash on hand I would recommend building the headway versions, it's pretty awesome.

Joon
Sep 25, 2021, 06:04 AM
Registered User
Thread OP
There was a request for more photos Again the headway version is sort of advanced. It was designed to be as compact as possible. The SLA version is much easier to build.


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