Amateur radio, programming, electronics and other musings

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I’ve been selling these distribution boxes all over the world and have been really pleased with the interest. I decided I would build another one for myself for use with the 48v SSPAs I have. I uprated the resistors and the capacitors. Here is the finished result.

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2014-03-22-22.03A DIY DC distribution system based around the popular Anderson Powerpole connectors.

Ideal for amateur radio applications or even RC enthusiasts who wish to connect several batteries in parallel to charge.  The kit contains everything you need to build the project including a professionally machined ABS enclosure.

You could mount one if these in the car, under your shack bench or include it in your “go” bag for portable use.

There is a single input fuse which if removed will isolate all other items connected from the power.

The Details

  • Printed circuit board .062 FR4 material, extra heavy 3oz. copper, with large high current traces.
  • Double sided, plated through holes, solder mask over bare copper, silk screened commercial grade printed circuit board.
  • Enclosure: ABS black plastic with CNC milled slots.
  • Power connectors: Anderson Powerpoles®.
  • Connectors are arranged according to the ARES/RACES standard.
  • Fuses are standard ATC/ATO automotive fuses available in 10 values from 1 to 40 Amps.
  • LED lights up to help identify which fuse is blown.
  • PVC threaded mounting standoffs.


  • 1 fused input
  • 5 fused outputs
  • LED lights when fuse is blown
  • Maximum 40A handling

What is Included?

You will receive a PCB and all of the components required to populate it.  You will receive a 4 page document explaining how to construct it. There is nothing complicated with building this and as long as you have a reasonably powerful soldering iron you should be fine.

You will also receive an ABS enclosure and standoffs. The enclosure has been commercially machined so there is no work required from you.


£35 + postage

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I created a template for the Power Pole enclosure using Eagle by adding all of the elements to a layer called milling. This meant I was able to precisely see where the cut-outs and holes should be milled out of the enclosure.

I exported to DXF from Eagle and tried to convert that to G-code but there must be something up with the export as most applications failed to read the file properly. To get around this I printed to a PDF and then imported the PDF into InkScape. I then resized the canvas to fit the import and saved that as a DXF file.

I then used dxf2gcode to convert the file to G-code. This worked pretty well. I then used a tool called OpenSCAM, an Open-Source software which can simulate 3-axis CNC machining to load and render the G-code file.

Now I have the G-code generated I just need to find the time to test the CNC machine I built for the first time.



Power Pole PCBsI have started to receive all the stock for 50 distribution boxes. The PCBs have arrived and the rest of the hardware will trickle in over the coming days.

I am now in a position to calculate the price of each unit and will do so over the next few days whilst writing the build instructions.

If you are interested in a unit (or more), please email me and I will then let you when I’ve posted the information.