WARNING: The project contains a high voltage module, take care when opertating this, it can cause a shock or stop your heart!
Misconfiguring it can also output 300VDC+.

The PCB gerbers are available on EasyEDA.

Explanation of component values are explained in the YouTube videos as well the the Blog, see links to the left.

I have mostly chosen premium components, it is possible to make this using cheap components from Ebay.

A lot of the components are SMD, the smallest being the SOD-123 diodes. It takes a bit of patience, steady hand, good flux and a soldering station to get good results. I used a PCB vice to hold the PCB and just use my fingernail to keep a component in place when I solder. I complete each solder in under 0.5 seconds, any longer and my finger will burn.

Of course no project would be complete if I did not build a prototype, I spend many days testing using a breadboard, and many months designing the schematics and PCBs:

At certain points of the build stage I tested to make sure the PCB works, here I'm testing the battery charging:

I decided to use perspex to make the amp case, I prefer this as I like to see my creation and it's easy to work with. I cut perfectly straight lines using a tenon saw and use fine emery paper to get the smooth finish.

To make all the mounting holes I use a cheap equivalent of the dremel, the most important thing is to have a precise drill press. I use the Dremel drill press which is compatible with my non Dremel drill.

Once all the PCBs are ready, it's time to start fixing them to the middle layer of the Perspex, all the PCBs have 2mm mounting holes, so it's just a case of making the holes and mounting them. Here is the rear panel PCB which is screwed to the 5mm thick Perspex:

All the wiring is done using JST connectors to make it easy.

That is all, for me using Perspex made making the case easy. The hardest part was thr design and testing. I make several prototypes on PCB before I fixed all the problems. I think I ended up making the battery protection 6 times because I was an idiot and did not ground myself and damged the mosfets.