THE GOAL: Im trying to come up with a design for easy to make, reliable, waterproof, modular enclosures that could fit many deck types. Not everyone has access to large vacuum forming equipment, large format cnc’s or space to work with fibreglass. I hope that smaller modular enclosures would be easier to diy at home or be made by the community and shipped to others. The idea here is to make customised modules for different hardware where each module is sealed and waterproof and ideally easy to modify or swap out.
WHERE IM AT: My current board has a cnc’d enclosure built for dual focbox, bestech bms and spaces for receivers and Bluetooth.
This is a work in progress but the plan is that an enclosure like this makes diy super easy, you just need to make a separate battery pack and your good to go. All your expensive / dangerous electronics are kept safe and dry.
WHERE I NEED HELP: I have encountered a few problems so far that i would like help to find solutions to.
The main problem that im having is connecting segments together. I would like individual segments to remain waterproof. It seems that this is not an easy challenge with high gauge cables that are not that flexible. I have considered using metal bars between the segments to secure segments and also carry current however this does not seem super safe. Also bms needs many smaller connections however these must remain reliable for good balancing over lifetime.
Also mounting to a flexy deck seems difficult. Solid mounting segments means flex may cause separation of segments under load. How can we keep electrical connections reliable under this scenario? if you accept that you need direct connections between segments to keep things waterproof then how do you stop stress on cables?
and is also fully waterproof. Im not sure how achievable this is, its been driving me crazy trying to think of solutions.
Any ideas about reliable connections between modules or how to deal with flex movement?