The battery I have is wrapped in brittle plastic. One small tear and it looks like this will spread far and spill the innards.
This battery went on only a handful of outings before this started.
I’ve made other things from “expanded PVC” which has 2 PVC skins with PVC foam in the middle. I’ve usually used the stuff that’s 3mm thick.
Please excuse the glare, that’s 74g. The naked battery is 813g.
It cuts easily with hobby-knife, razor blade, or table saw. Cyanoacrylate (super glue) joins it very well and can also seal the exposed foam at the cut edges. I have made other protective boxes out of this stuff. Stepping on a box will dent the PVC but the boxes have survived so far.
This 6Ah battery is much larger than I need so I’ll get a 3Ah battery. The box for that will capture the Anderson connectors the way that @DL2SBA did with his 3D-printed case.
These batteries include thermal protection. I wouldn’t expect overheating to be a problem with the 2A draw for a KX3 or the 2A charging current even including the added insulation of PVC foam.
This battery in the box has gone on only 2 outings, including Tunk Mtn for the TA-S2S. I’m happy to have a more durable cover for the battery.
3D printing looks great. Cutting and glueing this expanded PVC doesn’t require learning any additional software!
Just thought I’d show another option.
Dave
W1ETC