In order to safely and securely tap into the F3800's battery port, I designed a 3D printed connector that uses 5.5mm bullet connectors as the terminals. This is not an exact replica of the OEM plug, but it performs more than well enough to do the same job. It does fit the port very tightly, so be sure to press it in as far as it goes.
This is the "DIY Kit", and it includes all the parts needed to assemble a connector yourself, using your own supply of wiring.
Parts included: (1) main housing, (2) plug locks, (4) 5.5mm bullet plugs, (2) M3 x 10mm bolts
Directions: You will need to first solder your own selection wiring to the 5.5mm bullet plugs. Then, once cooled, insert the plugs into the housing and secure them with the included hardware. Done!
I recommend using 10AWG or 8AWG fine-stranded copper wire for best results. In my testing, I found that anything smaller than 10AWG runs the risk of overheating when the F3800's inverter is under heavy load. In terms of fitment, just make sure your wire's external diameter is somewhere around 6.0mm (1/4"). The connector housing locks are designed to lightly "grip" onto the exterior of the wire insulation, so you may experience fitment issues with higher gauge or abnormally thick insulation. If you plan to use beefier wires, let me know and I can send housing locks with a slightly larger opening.
There are several other configurations to choose from (listed separately):
- "Assembled Connector" is the fully assembled connector, ready to go out of the box. It comes pre-soldered with 10AWG x 4 tin-plated pure copper wires.
- "Complete Package" is the fully assembled connector, plus a 100A two-pole DC breaker and enclosure, fully wired up and ready to connect directly to a 51.2V battery.
Note: If you are interested in making any customizations or additions to one of these configurations, please contact me directly and we'll work something out!
