Build This DIY Emergency Power Tool for Your Home!

In this project, we’ll build a DIY Emergency Power Box that works as both a USB mobile charger and a variable voltage power supply—all powered by 18650 lithium-ion batteries.

This compact, multi-purpose device is perfect for:

1. Charging smartphones and USB devices
2. Powering small electronics like routers, LED strips, and Arduino projects
3. Serving as an emergency power backup during power outages

At the heart of this project is the XL6009 boost converter, which allows adjustable output voltage (3v to 30v), along with a built-in USB power bank module for 5V charging. A mini voltmeter displays the live output voltage, so you can easily monitor and adjust it based on your needs.

Whether you’re a student, hobbyist, or electronics enthusiast, this is a simple yet highly useful DIY tool to have at home or carry on the go!

Let’s get started!

1. XL6009 Boost Converter Module – 1 pc
2. 18650 Li-ion Batteries – 2 pcs
3. 18650 Battery Holder (2-cell) – 1 pc
4. USB Power Bank Module – 1 pc
5. Mini Digital Voltmeter (0.28”) – 1 pc
6. Banana Socket (Red & Black) – 1 pair (for adjustable output from XL6009)

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

1. Use a multi-input power bank module (with USB 2.0, Type-C, MicroUSB, and a small digital display).
2. Place the module on the top center area of the acrylic sheet (next to the battery holder).
3. Mark the mounting hole positions of the module on the acrylic sheet using a marker.
4. Use a small drill bit to carefully drill holes at the marked points.
5. Insert spacers or nylon standoffs into the drilled holes.
6. Align the module with the spacers and secure it using screws or glue if screw mounting is not possible.
7. 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.

1. Take the XL6009 boost converter module.
2. Decide the mounting position — place it on the side edge of the acrylic sheet (left or bottom side, depending on space).
3. Align the XL6009 on the acrylic and mark the two mounting holes.
4. Carefully drill two holes using a small drill bit.
5. Insert spacers or standoffs into the holes to raise the XL6009 module slightly above the surface.
6. Place the XL6009 on top of the spacers and secure it with screws from above.
7. 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.

1. Take a thick copper wire (you can strip it from old power cords or use single-core wire).
2. Bend the copper wire into a U or T shape so it can connect three points:
3. 
   
4. 18650 Battery Holder negative (–) terminal
5. XL6009 module GND (–) input pin
6. Power Bank Module GND (–) input

1. Trim and shape the wire to fit neatly between these three points.
2. Solder the copper wire ends to all three negative terminals:
3. One end to battery holder’s – terminal
4. One end to XL6009’s GND input
5. One end to Powerbank module’s GND input

1. Take another piece of copper wire (solid-core preferred for stability).
2. Bend and shape the wire to run along the path from:

1. The +ve terminal of the 18650 battery holder
2. To the +ve input terminal of the Power Bank Module

1. Ensure the wire is properly routed and doesn’t touch other components.
2. Solder one end of the copper wire to the battery holder’s +ve terminal.
3. Solder the other end to the Power Bank Module’s +ve input.
4. 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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🧾 Simple Ordering Steps:

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1. On the previous copper wire (which runs from battery +ve to the power bank module), locate a clean scratch point where you exposed copper.
2. Solder one terminal of your ON/OFF switch (rocker or slide type) to this scratched copper point.
3. Take another bent copper wire and connect it from the other terminal of the switch to the +ve input pin of the XL6009 module.
4. This setup ensures the XL6009 module receives power only when the switch is turned ON.
5. 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).

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

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

1. After completing the circuit and confirming all connections, it’s time to enclose the device for safety and a neat look.
2. Use 3mm thick white acrylic sheets for the enclosure — cut using a laser cutter (or manually, if needed).
3. Design and cut 4 side panels and 1 top cover, with proper cutouts for:

1. USB-A, Type-C, and MicroUSB ports of the power bank module
2. Banana sockets (output)
3. ON/OFF switch

1. Carefully align and place each acrylic panel around the circuit:
2. Fix the left, right and back panels one by one using hot glue or acrylic glue.

1. Insert 2× 18650 batteries into the holder.
2. Cut a clear 3mm acrylic top to match the device size.
3. Drill a small hole above XL6009 trimpot (for voltage adjustment).
4. Place the clear top and glue it securely.
5. Make sure:
6. 
   
7. Trimpot hole aligns for easy access.
8. Batteries are visible.
9. All ports and display are accessible from the sides.

1. Charge the device via Type-C, Micro-USB, or USB-A input.
2. The Power Bank Module lets you charge mobile, earphones, etc. using its 2 USB-A output ports.
3. Side power switch controls the XL6009 boost converter.
4. 
   
5. When ON, the voltmeter and XL6009 activate.
6. 
   
7. Use the trimpot (via top hole) to adjust output from ~3V to 30V DC.
8. Output available via banana sockets (Red = +, Black = –).

Want to see it in action?

👉 Watch the full YouTube video and enjoy the build!