XT90 Power Bar

XT90 Power Distribution bar. Used for our 24V solar charging system at our flying field.

We used XT90-S sparkfree connectors as we were getting sparks at 24V with our previous banana plug distribution boxes.

Printed on ABS @ 25% infill. At least 2 outer layers so screws don't break walls when threaded.

Used 10AWG wire, but 8AWG or lower would be fine - adjust to your requirements.

Important to use wire with a silicone sleeve and leave the sleeve intact between connectors so it protects the print while soldering. I used a wire stripper to cut the silicon sleeve before and after the XT90 connectors, and then a slim wire cutter to cut between the two cuts and remove the sleeve. Lots of flux on the wire before soldering, and plenty of solder to create a positive electrical and mechanical connection.

Supports only required on the bottom, for the screw holes.

4 x M3x16 screws for end/input.
2 x M3x12 screws for bottom.

I used a bit of super glue on the top and botto