Fuse and splitter boards that use Anderson PowerPole 45-amp connectors.
I assembled the initial boards (distribution board and fuse board small v1.1, fuse board large v1.0). Everything works fine. I made a few small tweaks after building this revision:
I haven't tested these changes yet, but they are pretty low-risk.
I applied a moderate load to boards for testing. I used a 100W, 2 ohm resistor with a 12V, "10A" power supply, and measured the voltage drop at the farthest connection point from the source. The power supply is cheap, so it drooped to 11.5v during testing, for a load of ~5.75A.
|Board||Voltage drop||Calculated resistance, ohms|
|Fuse board large||0.03v||.0052|
|Fuse board small||0.04v||.0070|
These numbers are pretty approximate. They suggest that the resistance of the board is low enough to be negligible at reasonable loads.
Here are the assembled boards:
Upload the zip file from the gerber directory of the board you'd like to make to a fab house. I use JLCPCB, which is generally cheapest, and quite fast. The default specifications are fine - feel free to change the color, of course!
The 'Components' section lists the part numbers. Take a look at the photos for help in figuring out how many of each component you'll need. For the large fuse board and distribution board, you have the option of using a straight or right-angle connector for the 'in' connector.
You can check Octopart to see part prices from a bunch of common distributors.
Since the large power traces on the PCBs act as giant heatsinks, you'll need to be patient when soldering the components. It'll take longer than usual for everything to heat up enough that solder flows around the entire joint, making a clean connection. I set my iron to about 360C - it's worth experimenting to find the setting that works for you. Too cold and it'll take a long time to solder, but too hot and you risk burning the board or the flux. It takes me about 20 minutes to solder the small fuse board, and 45 minutes for the large fuse board.