Solar Charged DC powerbox

I needed a method to get power to my test rigs. Since the Linksys routers run on 12v, I figured this would be the best bet. I had some old 12v 5.2 amp hour batteries from an old ups. They had cracked at the bottom, so I purchased a replacement at my local Fry's electronics. I chose a 12v 7.2 amp hour, sealed lead-acid. I purchased a Sunforce60032 30 amp Digital Charge controller, and 2 1.8 watt Sunforce solar cells. I chose the larger, more expensive controller so I could use it for a house mounted system I am designing. You can get by with the 7 amp model.

I found a plastic container that was real tupperware from the late 50s that used to be my grandmas. A little paint, and a few holes for the wires and venting. There is an inline fuse holder with a 3 amp fuse for the load. The wiring is a bit shoddy, but this is a prototype. The main switch I harvested from a leaf blower that had died a week before.

The external connection is a molex plug. The two other connectors are for the Sunforce photo-voltaic cells.

And here we can see voltage on each of the two switch settings. Low and High respectively.

Here shown plugged into the WAP.

I have used this for over a week. I can have 3 or so hours at medium 125mw radio output. It takes 6 or so hours full sun to charge it fully.