Hey everyone, wanted to share my recent DIY mobile solar power station build! My goal was to build a heavy-duty, high-capacity mobile rig on wheels that could easily power high-draw appliances like a portable AC and electric kettle, all for a fraction of the cost of commercial "solar generator" setups like Jackery, Ecoflow or Goal Zero.
Here is the full component breakdown and specs:
Core System Specs:
Battery Bank: 5,120Wh total energy (4x Kunlun Mini 100Ah 12V LiFePO4 batteries in parallel).
Inverter: Giandel 2200W Continuous Pure Sine Wave Inverter (with solar controller input).
Charge Controller: Renogy Rover 40A MPPT Charge Controller (mounted on side, configured for Lithium).
Monitoring: TR16 Battery Monitor with QWORK Shunt (coulomb counting programmed to 400Ah).
Safety & Fusing: 2 AWG pure copper main feeds, 250A ANL main fuse, 50A inline fuse on the charge controller battery line, and a 275A main disconnect kill switch.
Enclosure: Craftsman rolling system box with telescoping handle for total mobility.
Build Highlights:
Mobility: Everything is mounted directly to the rolling Craftsman box, keeping 5kWh of battery capacity mobile without needing to haul heavy separate components around.
Proper Shunt Integration: Routed all negative loads and charger grounds through the QWORK shunt's P- stud so the TR16 monitor accurately tracks net charge/discharge current.
Safety First: Isolated the positive line with a 275A rotary kill switch and an inline 250A ANL fuse block before reaching the inverter terminals. Included a dedicated 50A inline fuse on the positive run between the battery and the Renogy Rover controller.
Testing & Performance:
Kettle Stress Test: Stress tested with a ~1,470W electric kettle (~135A DC draw). Voltage held rock solid without excessive sag, and cables stayed well within thermal limits.
AC Unit: Planned usage is running a Hisense portable AC (~700W–800W continuous). Based on initial draws, expecting around 5.5 to 7 hours of continuous runtime on a single charge.
Total Cost: Built for roughly ~$1,200 total—giving me over 5.1kWh of stored energy compared to commercial units that charge $3,500+ for less capacity.
Happy to answer any questions on the wiring layout, components, or testing! Let me know what you think!