Enhanced LiFePO4 Battery Cap

I made this for use with a 7AH LiFePO4 battery. The nominal dimensions were 65mm wide & 150mm long ( 2.55" X 5.94" ). The dimensions for this battery are also shared by some vendors' 10AH and 12AH batteries.  The provided model includes a power switch, a voltage display and 4 Anderson PowerPole connector pairs with associated automotive style fuses.  The openings are sized for a 20mm round switch and 23mmx15mm voltage display.

Tips for assembly of the fuse & Anderson PowerPole components can be found with this model:   https://www.printables.com/model/535143-parameterized-f360-anderson-powerpole-fuse-block

The standoffs on all four sides are to provide room for wiring.  It is intended that servo-tape (double sided removable tape) be used to secure the cap on the battery, placing strips of tape on the battery at locations corresponding to the standoffs.  Install the cap with the gauge & switch at the opposite end of the battery from the terminals to reduce the potential of a short circuit.  I recommend using stranded wire with silicon insulation for easy manipulation during assembly & installation.

The battery I used came with F2 style terminals (also referred to as T2 terminals).   ¼" Female Spade Quickconnects can be used for attachment.  A 6.3mm female spade connector is also appropriate.   These connectors are also appropriate for populating the fuse connector openings.

After populating the fuse holder positions, you may need to use some form of glue (hot glue, gorilla glue, etc.) on the back sides to ensure the hardware remains in place when fuses are removed.  Fuses used are standard automotive fuses (roughly ¾" or 19mm wide), not mini's.

The Anderson PowerPole pair openings are snap-ins, but a provision is made for insertion of a length of straightened filament through their centers as reinforcement. See the opening at one end.  Glue can also be used if desired.

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Please note that Fusion 360 source is included. The design was parameterized to permit easy customization, allowing alternative switch, voltage display and battery dimensions.  It also allows specification of the number of fused Anderson PowerPole pairs to include.

If you want to use the F360 source to modify the model, the parameters used are as follows, all measurements in mm:

1. Battery_long  - battery length
2. Battery_wide - battery width
3. Switch_diameter  -  Round switch opening diameter, use 0.01 if switch is not round
4. Gauge_long - voltage gauge length
5. Gauge_wide - voltage gauge width
6. Gauge_deep - thickness of voltage gauge beyond rear panel mounting. 
7. Block_long  - Do Not Edit - Internal Use
8. Block_wide - Do Not Edit - Internal Use
9. Circuits - the number of fused Anderson PowerPole pairs
10. switch_R_border- the width of reduced panel thickness around a snap-in round switch - 0.01 if not used
11. switch_long - length of rectangular switch opening - use 0.01 if switch is not rectangular
12. switch_wide - width of rectangular switch opening - use 0.01 if switch is not rectangular
13. switch_s_boarder - the width of reduced panel thickness around a snap-in rectangular switch - 0.01 if not used
14. Standoff_height  - sets clearance between cap and battery top
15. walloverlap - wall height beyond standoff_height, how much overlap down the battery sides.

note:  if using a round switch specification, expect to see warnings for Extrude10 & Extrude11 features on the time line. This has no negative effect & is a side effect of provisions for using either round or rectangular switch  openings.

note:  To suppress creation of openings for switch and/or  gauge, use 0.01 for all related dimensions.