VictronEnergy Smart Shunt Shield

I wanted a method to attach the SmartShunt directly to a 120Ah battery. 

The main issue I faced was the large 10MM bolts on the shunt. The battery terminal was 8mm, and the accessories I connected were also 8mm, rather than a bunch of very short cables or cutting off the 8mm lugs and fitting 10mm ones.

I created this shield that fits snuggly over the SmartShunt and used a copper bar as the conductor, which is folded and has holes to attach to the Shunt, allowing an 8mm bolt to be used as a post on one end and an 8mm bolt to connect to the negative terminal. 

I also created a cover for the entire shield with cutouts for the accessory attachment, given the danger of creating a short by touching the exposed conducted and bolts. On my battery, I also had a small 1.5mm gap, which I created a small right angle adapter, which I glued onto the shield and then attached with double-sided tape.

Not shown in the photos is that I used cable ties to keep the cover attached. Also, I printed the shield on its side and used organic supports. The cover and bracket are printed with the top on the plate and require no support.

Parts Required

• 1x 8mm 25mm Bolt for Terminal attachment (or length as required)
• 1x 8mm 35mm Bolt for Accessory Post
• 2x 8mm Spring Washer
• 2x 8mm Flat Washer
• 200mm Flat Copper Bar (1.5mm x 20mm)

Instructions to Fold Conductors

1. Cut the flat bar into two 90mm lengths
2. Mark and square a line at 30mm on one end.
3. Clamp in a vice with a steel plate at the front and bend forward.
4. Mark and square a line at 35mm on the other end.
5. clamp in a vice with the first bend forward and the steel plate at the back,
6. Bend backward.

Drilling Holes in Conductors

1. Use the Shield as a template to mark the holes.
2. I choose to increase the diameter of the holes by 1MM. So the 8mm holes are drilled at 9mm and the 10mm holes at 11mm.
3. The conductors need to be clamped securely while drilling. They can quickly come loose and bend from the drill's torque (I speak from experience).

Disclaimer: Use this model at your own risk. I assume no responsibility for any damage or injuries arising from its use.