Yaesu FT-727R lithium-ion conversion part two

1 minute read

3D printing a new battery enclosure.

In part one a new chassis interface was designed, printed, and tested. Now it’s time to print and build the rest of the enclosure and test it out. Part three will be electronics and final assembly.

Here’s the rear of the enclosure with the three cells in position:

In 3D printing the orientation of your part can either make or break the print. What I’m saying is, align your print to utilize the anisotropic properties of the Z-Axis. An example of this is the battery door which you’ll see below.

This print didn’t come out the greatest, however it can still serve for test fitting components:

The charge jack also snaps into its home nicely:

As you can see the front of the battery cover didn’t print with good cosmetic results. The axis of the print was altered from face down on the z-axis to the face on the x-y axis. (the part is slightly curved) Since the tolerances are ok a second door was printed with much better results:

Here’s the charger and the pedestal it will be mounted to:

lastly comes putting the enclosure together with the charge controller in place. Also noteworthy is the stuffing tool to push the batteries against the housing’s base:

The two covers are designed as a C-channel type slip fit. It offers assembly without hardware and decent cosmetics.