PORTABLE LIFEPO4 BATTERY STATION
Off-grid power for construction sites, overlanding, and emergency backup
TOTAL BUILD: $915
Off-grid power for construction sites, overlanding, and emergency backup
Remote jobsites need portable, reliable power
Construction sites don't always have grid power. Excavation teams on remote land, equipment operators in valleys, and field crews running tools off battery all face the same problem: you need portable 12V power that weighs less than a diesel generator and costs half as much.
This portable LiFePO4 battery station solves that. It's a self-contained 1,280Wh system that runs AC tools, charges power tool batteries, powers LED lights, and keeps crew phones alive. The battery itself is lighter than a diesel setup, lasts 2,000+ charge cycles instead of hundreds, and requires zero maintenance. Built into a weatherproof case with an inverter, solar charger, and real-time monitoring.
Built by Errol Kerr (E Kerr LLC / Ruppert Excavation), this system is engineered for jobsites where power trucks can't reach and grid connections don't exist.
Bottom line: 8+ hours of continuous power, solar rechargeable, fits in a truck bed, and costs under $1,000 in parts.
Watch the portable battery station come to life
LiFePO4 Battery System Performance Data
System assembly, components, and field deployment photos
Everything you need, with direct Amazon affiliate links
System Specs: 1,280Wh capacity, 1,000W AC output, 100W solar charging, 2,000+ cycle lifespan, ~35 lbs complete weight.
Estimated Runtime: 8+ hours for LED lights and phone chargers, 1 hour for power tools at full load. Solar charge adds 20-25% daily in good conditions.
Step-by-step assembly and commissioning guide
Start with a 50-caliber ammo can or equivalent Pelican case. This is your weatherproof container. Clean the interior and install adhesive-backed rubber isolation pads on the bottom to dampen vibration and prevent battery sliding. The battery, inverter, and fuse block will mount inside. Leave adequate ventilation—drill or cut 4-6 small vent holes in the case bottom and top to allow passive airflow and prevent heat buildup during charging.
Mount the LiTime 100Ah LiFePO4 battery on the isolation pads. This is the heaviest component. Secure it with padded brackets or rope to prevent movement. The battery's built-in BMS (battery management system) requires no external fusing on the output, but you'll add a disconnect switch and fuse block for the main load. Connect the battery's positive and negative terminals using the supplied 4AWG cables with crimped lugs—NO SOLDER. Use a professional 4AWG crimper for solid connections rated for 100A continuous.
Run the 4AWG positive cable from the battery through the main disconnect switch (rated 300A), then to the positive bus of the Blue Sea Systems fuse block. Wire the negative cable directly from the battery negative to the negative bus of the fuse block. Install a 100A fuse in the disconnect switch line (within 18 inches of battery positive). This isolates the entire system. Label all connections with heat shrink: RED for positive, BLACK for negative. Verify polarity before powering anything.
Mount the BESTEK 1000W inverter on the fuse block's output (use a 100A Anderson SB50 connector for clean disconnection). Install the Victron BMV-712 battery monitor shunt between the battery negative terminal and the fuse block negative—this measures all current flowing in/out. Connect the shunt to the monitor display unit via twisted-pair cable (shielded to prevent noise). The inverter output connects to AC outlets that mount on the case exterior or through a panel connector.
Run MC4 connectors from the 100W Renogy solar panel to the Victron SmartSolar MPPT 75/15 charge controller. Wire the controller output (Anderson SB50 connector) to a separate 50A breaker on the fuse block, then to the battery positive. The MPPT controller regulates charging to prevent overcharge. Install the solar panel on a roof mount, ground stand, or trailer frame. The MPPT has Bluetooth for monitoring charging status. Connect the controller to the battery through a dedicated fuse (50A) on the fuse block.
Mount the 12V USB outlet panel on the case exterior for direct 12V charging (bypasses inverter for efficiency). Connect all heat shrink tubing over spliced connections. Test system voltages: Battery should read 13.0-14.0V at rest. Switch on the inverter and verify 110V AC output at the case receptacles. Let the solar panel charge the battery for 1-2 hours while monitoring voltage. The BMV display should show charging current. Run a 30-minute load test with the inverter powering an LED light or charger. Voltage should stay above 12.0V under load.
Apply marine-grade silicone sealant around case seams and cable entry points. Place the unit on a flat, level surface in the truck bed or trailer. Secure the solar panel with cable ties or clamps. Place the 12V USB outlet panel where crew can access it easily. Run the inverter's AC cord through a weatherproof rubber grommet. Test the full system one more time: discharge the battery to 50% using the AC loads, then verify solar recharging. Document voltage, current, and runtime values. You're now ready for jobsite deployment.
Real-world performance metrics from deployed systems
Full energy storage provides 8+ hours of continuous power for lights and chargers, or 1 hour for power tools.
LiFePO4 chemistry outlasts lead-acid 10x over. 2,000 full cycles = 5+ years of daily jobsite use.
Adds 20-25% daily charge in full sun. Zero fuel cost for ongoing operation. Renewable energy on remote sites.
~35 lbs complete unit fits truck bed, can be carried by two people. No generator noise or exhaust fumes.
1,000W continuous output powers drills, grinders, saws, LED lights, and DEWALT battery chargers. 2,000W surge handles startup current.
Dual USB outlets charge phone and radio simultaneously. 12V outlet powers inverters or auxiliary loads. 100+ full phone charges per battery cycle.
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