Dewalt 20v Max power tap

These components can be assembled, by stacking, to construct various items powered by the Dewalt 20v max batteries.   Three examples in the pictures are a power tap with anderson powerpole connectors, a power tap with a pigtail, and a three place USB 5v 3A charging stations.  Configurations can include a cap with a cutout for a voltage readout.

In the examples shown, the voltage readout was of this type:  https://www.amazon.com/gp/product/B00YALUXH0

The USB 5v chargers were of this type: https://www.amazon.com/gp/product/B01HXU1C6U

The Anderson powerpoles used are this style connector: https://powerwerx.com/anderson-powerpole-connectors-30amp-unassembled

The battery connection terminals were cut from 1" x 1/32" brass stock.  Each was an 8 - 9 mm slice off the end.  For me, the easiest way to cut was to scribe on both sides, then use pliers gripping next to the scribed line to flex back & forth until the piece fractured off.

I used this source for the brass stock: https://www.amazon.com/PRECISION-METALS-8242-Metal-Strip/dp/B002SATHCW

The components consist of the following, all named “dewalt 20vmax power tap” with an appended identifier.

Part                          Description

A -  the base component that engages the battery

Bn - a middle layer component that is attached to A via two 3mm screws

B1 - version with two cutouts to accomodate USB charger boards

B2 - version with one cutout to accomodate a USB charger board

B3 - version with one cutout to accomodate a pair of 14 awg wires.

B4 - version with one cutout specific to accomodating a joined pair of Anderson power pole connectors.  It has a pair of ribs that engage the depressions on the connector sides to hold them securely in place.

Cn - a component that snap fits to a B component. It may be a cap or expansion space.

C1 - A cap with a solid top.

C2 - A cap with an opening sized for a voltage display.

C3 - An expansion space to accomodate a device up to 80mm x 50mm x 17

Dn - A cap for a C3 component

D1 - Solid cap

D2 - Cap with opening for voltage display

All components should print without need for supports. The electrical contacts should be mounted through both A & B components used.  Users may want to include an appropriate fuse for their application, either internally or externally.  I used servo tape for securing electronics in place.

Some early versions seen in the pictures had A&B components glued rather screwed together. Using screws limits the USB charger build to  two ports rather than three.