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Remove a section of the insulation.Pick a spot in the middle of the USB cable and use a sharp knife to cut through the outer insulation only. Make your cut about the same length as the PowerBoost PCB. Then peel back the insulation to expose the braided shield. |
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Separate the wires from the shieldCut away the insulation and separate the shield wires to expose the wires inside. If there is a foil wrapper around the wires, remove it.
The Red and Black wires are the Power and Ground wires. The White and Green wires are the Data wires. |
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Cut and Strip the Power and Ground WiresCut the power and ground wires. Strip off about 1/4" of isulation from each side. Leave the white and green data wires intact. |
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Solder the 'A' side wires:These are the inputs to the PowerBoost.
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Solder the 'B' side wires:These are the outputs from the PowerBoost.
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Insulate the bare wiresFold a piece of electrical tape over the bare shield wires. This will prevent any short circuits from the bare wires. |
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Secure with 'Zip' tiesFold the insulated shield wires down on the back of the PowerBoost and secure the ends with 3" 'zip' ties and trim the ends. |
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Test itPlug in a battery and make sure that everything is working. |
Wrap it up!
For the prototype here, we soldered the battery leads directly to the BAT and GND pins. Then slid the whole thing into a piece of translucent 3/4" heat-shrink tubing for a nice compact in-line package.
