Build This DIY Emergency Power Tool for Your Home!

Step 1: Mount the Battery Holder on Acrylic Sheet

• Use a 3mm white acrylic sheet as the base for your DIY power device.
• Cut the acrylic to a suitable size (e.g., 10cm x 8cm).
• Take a 2-cell 18650 battery holder.
• Position the battery holder on the top-right corner of the acrylic sheet (as shown in the image).
• Apply strong glue (hot glue or Fevikwik) to the bottom of the holder.
• Press it firmly onto the acrylic surface and let it set.
• Ensure the wires from the holder are easily accessible for later connections.

Step 2: Mount the Power Bank Module

• Use a multi-input power bank module (with USB 2.0, Type-C, MicroUSB, and a small digital display).
• Place the module on the top center area of the acrylic sheet (next to the battery holder).
• Mark the mounting hole positions of the module on the acrylic sheet using a marker.
• Use a small drill bit to carefully drill holes at the marked points.
• Insert spacers or nylon standoffs into the drilled holes.
• Align the module with the spacers and secure it using screws or glue if screw mounting is not possible.
• Ensure the USB ports and display are properly visible and accessible from the top/front.

📌 Tip: Be careful while drilling acrylic—use low speed to avoid cracks.

Step 3: Mount the XL6009 Boost Converter

• Take the XL6009 boost converter module.
• Decide the mounting position — place it on the side edge of the acrylic sheet (left or bottom side, depending on space).
• Align the XL6009 on the acrylic and mark the two mounting holes.
• Carefully drill two holes using a small drill bit.
• Insert spacers or standoffs into the holes to raise the XL6009 module slightly above the surface.
• Place the XL6009 on top of the spacers and secure it with screws from above.
• Make sure the adjustable potentiometer and terminals are easily accessible for voltage adjustment and output wiring.

📌 Tip: Keep enough space around the module to avoid touching other components during use.

Step 4: Connect the Common Ground (Negative)

• Take a thick copper wire (you can strip it from old power cords or use single-core wire).
• Bend the copper wire into a U or T shape so it can connect three points:
• 18650 Battery Holder negative (–) terminal
• XL6009 module GND (–) input pin
• Power Bank Module GND (–) input
• Trim and shape the wire to fit neatly between these three points.
• Solder the copper wire ends to all three negative terminals:
• One end to battery holder’s – terminal
• One end to XL6009’s GND input
• One end to Powerbank module’s GND input

Step 5: Connect Battery Positive to Power Bank Module

• Take another piece of copper wire (solid-core preferred for stability).
• Bend and shape the wire to run along the path from:
• The +ve terminal of the 18650 battery holder
• To the +ve input terminal of the Power Bank Module
• Ensure the wire is properly routed and doesn’t touch other components.
• Solder one end of the copper wire to the battery holder’s +ve terminal.
• Solder the other end to the Power Bank Module’s +ve input.
• To help solder stick better, you can gently scratch a small portion of the copper wire at the soldering point to remove oxidation and expose fresh copper.

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Step 7: Add ON/OFF Switch for XL6009 Power Control

• On the previous copper wire (which runs from battery +ve to the power bank module), locate a clean scratch point where you exposed copper.
• Solder one terminal of your ON/OFF switch (rocker or slide type) to this scratched copper point.
• Take another bent copper wire and connect it from the other terminal of the switch to the +ve input pin of the XL6009 module.
• This setup ensures the XL6009 module receives power only when the switch is turned ON.
• After confirming the connection, use hot glue or Fevikwik to fix the switch securely onto the acrylic sheet in a convenient spot (e.g., front side or top edge).

Step 8: Install and Connect the Banana Sockets (Output)

• Solder a wire from the XL6009 VOUT+ (positive output) to the red banana socket.
• Solder another wire from the XL6009 GND (negative output) to the black banana socket.
• Make sure the sockets are firmly glued and the solder joints are strong.

Step 9: Mount and Connect the Mini Voltmeter (0.28”)

• Take the 0.28” digital voltmeter module (typically with 3 wires: red, black, and yellow or only red/black).
• Place it above the ON/OFF switch on the acrylic sheet (as shown in your reference image).
• Apply hot glue or strong adhesive to the back of the voltmeter and secure it in place.
• Solder the black (GND) wire of the voltmeter to the GND of the XL6009 module (same point as black banana socket).
• Solder the red (VCC) wire of the voltmeter to the XL6009 output +ve (same as red banana socket).
• If your voltmeter has a third wire (yellow or white) for measurement, solder it to XL6009 VOUT+ as well.

Step 10: Enclose the Circuit With 3mm White Acrylic Panels

• After completing the circuit and confirming all connections, it’s time to enclose the device for safety and a neat look.
• Use 3mm thick white acrylic sheets for the enclosure — cut using a laser cutter (or manually, if needed).
• Design and cut 4 side panels and 1 top cover, with proper cutouts for:
• USB-A, Type-C, and MicroUSB ports of the power bank module
• Banana sockets (output)
• ON/OFF switch
• Carefully align and place each acrylic panel around the circuit:
• Fix the left, right and back panels one by one using hot glue or acrylic glue.

Step 11: Insert Batteries and Add Clear Top Cover

• Insert 2× 18650 batteries into the holder.
• Cut a clear 3mm acrylic top to match the device size.
• Drill a small hole above XL6009 trimpot (for voltage adjustment).
• Place the clear top and glue it securely.
• Make sure:
• Trimpot hole aligns for easy access.
• Batteries are visible.
• All ports and display are accessible from the sides.

Step 12: Power Up & Usage

• Charge the device via Type-C, Micro-USB, or USB-A input.
• The Power Bank Module lets you charge mobile, earphones, etc. using its 2 USB-A output ports.
• Side power switch controls the XL6009 boost converter.
• When ON, the voltmeter and XL6009 activate.
• Use the trimpot (via top hole) to adjust output from ~3V to 30V DC.
• Output available via banana sockets (Red = +, Black = –).

Step 13: Watch the Full Video!

Want to see it in action?

👉 Watch the full YouTube video and enjoy the build!