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Assembly Instructions

  • Cut the battery cable to size and strip the wires. Red wire should be approx. 45 mm and black wire approx. 90 mm long.

  • Solder the black wire to the battery tab as seen in the pictures.

  • Arrange the lithium batteries using the battery welding base (3D printed, STL file available here).

  • You can use a hot glue gun to fix the batteries in place as seen in the pictures.

  • Weld the battery tab to the negative side of the batteries. We are using 2P at 5.5A settings for spot welding.

  • Remove the batteries from the battery welding base.

  • Disassemble the JST connector and remove the red wire from the battery cable.

  • Solder the red wire to the other battery tab as seen in the picture.

  • Add some adhesive sealant between the batteries around the black wire. Run the black wire through the other battery tab and then weld the battery tab to the positive side of the batteries using the same settings for spot welding.

  • Remove hot glue and add some more adhesive sealant around and between the batteries.
    Be careful: The sealant should only be used on the front and back of the battery pack but not on the left or right side. The sealant should not exceed the height of the batteries. When adding the adhesive between the batteries, leave enough space on the top for the 3D printed battery holder that will be added to the battery pack in the next steps.

  • Leave the battery pack to cure for approx. 24 hours.

  • Add the battery foam to the negative side of the battery pack.

  • Add the battery holder to the positive side of the battery pack. Watch out for the cable.

  • Using the M3 tap drill, cut the thread into the RangerEdge holders. There are two M3 holes on the RangerEdge holder bottom and one M3 hole on each RangerEdge holder top.

  • Using the 2.5mm drill bit and countersink drill bit, redrill the two longer holes on the RangerEdge holder bottom if needed.

  • Attach the RangerEdge holders to the top side of the RangerEdge electronics using the M3x6 screws as seen in the picture.

  • Insert the RangerEdge electronics into the enclosure case and secure it in place using the M2.5x12 screws as seen in the picture.

  • Insert the battery pack into the enclosure case and connect it to the RangerEdge electronics.

  • Place the O-ring gasket into the groove on the enclosure case.

  • Attach the enclosure lid using M4x12 and M4x16 screws using the cordless power screwdriver.

  • Engrave logos and serial number onto the enclosure using the fibre laser marking machine.

  • Add the magnet and "Remove before deployment" sticker.

Toolset

  • FDM 3D printer - We are using Original Prusa i3 MK3S+ 3D printer with satin powder-coated sheet and Prusament PETG filament, but any other similar 3D printer is also suitable

  • Battery spot welding machine - We are using Sunkko 709AD+ battery spot welding machine, but any other similar machine is also suitable

  • Fibre laser marking machine - We are using 20W fibre laser marking machine, but any other similar machine is also suitable

  • Cordless power screwdriver with HEX2.5 screwdriver bit - We are using Bosch GO Professional cordless power screwdriver, but any other similar screwdriver is also suitable

  • Philips screwdriver PH1

  • Soldering iron

  • Hot glue gun

  • Adhesive sealant DOWSIL 744 RTV and caulking gun

  • Cordless drill with 2.5mm drill bit and countersink drill bit
  • Tap holder with M3 tap drill