Makita 40V Power Supply

This is a full build of a power supply based off my previous 18V version, but that again is off of Volon's original design for the 18V adapter plate.  This had a whole new redesign of the adapter to fit properly to the 40V Makita Battery.

The design still uses the same threaded inserts for the brass blade contacts that actively maintain good conductance and secure the blade firmly.  Brass is a good choice as it has good wear properties so will work well with the battery contacts over time.

The case meant to house a UCTRONICS Variable power supply, and nicely leverages the 40V Makita battery, allowing anything from 0-38V of output, with the ps allowing set caps for voltage, amperage, or wattage limits.  The case top has 2 simple locking lugs with only a screw to secure, this would make access easy for assembly.

Overall build uses the following:

1 - UCTRONICS Numerical Control DC 6-55V to 0-50V 5A Step Down Stabilized Power Supply (model# U5168)

1 - 4mm long M3 threaded inserts (in adapter to secure case)

2 - 9.5mm long M5 threaded inserts (sides of adapter plate)

1 - 12mm M3 bolt (for attaching case to adapter)

2 - 12mm M5 bolts to secure brass inserts

2 - Banana Plug Jacks

2 - brass contacts (mine where .85 mm thick, should work well with upto 1mm)

For brass contacts, use the Test Blade file to mark the brass for 2 items, and the location of the 5mm hole.  Note the absolute accuracy isn't necessary, just roughly 10mm x 58mm x .85mm.  For brass final piece, just make sure the hole lines up with the adapter plate bolt hole, and the length does not exceed the front guide.  NOTE, use the open access holes in adapter to make sure the threaded inserts are not fouled with plastic.  this method also allows clean access to secure the first brass blade, the other will either have to use an a short allen key or ballnose key.

Assembly is fairly straight forward, as once the blades are secured and wires passed through to top, the ps module has a simple jack to secure the wires for input (from battery) to output (banana lugs).

Included in the files as mentioned is a test blade for marking and drilling brass contacts.  There is also a full plate of case, adapter and test blade.  As was supplied from previous set, I have included the .f3d and .step files as the case top can be modified.