I've struggled to install my Elcon PFC 2500 in a way that is easy to use and I'm comfortable with since I bought it a year ago.
Carrying it on the Zero luggage racks is okay for the charger because of its IP67 weatherproof rating. However, the Zero's luggage system should really not be taxed that way, and I've noticed what one charger can do over time, whether in a side case or a top case.
So, for a while now, I rolled it up in a towel and threw it and the cables into a waterproof duffle bag and strapped it to my rear seat and top case. I used a Givi top rack for the Maxia case for upper bracing. I had the rollover opening face forward so I can unload the cables and Elcon without undoing the straps.
This allowed me to carry it where the bike is rated to support a passenger, fill in the aerodynamic gap between my back and the tail case, and make the top rack a little sturdier by dampening the load it experiences going over bumps.
However, the duffle rollout took time and was wearing on my cable setup, and I had Hollywood Electrics inspect and fix some looseness that could have grown into a problem.
All of this to say that I scrounged for a Pelican case of the right size and I intend to mount it by giving it attachment points and using similar bracing as the duffle.
Here's my mockup on my old trusty 13DS:
And here's the charger layer out with cables inside how I intend to fasten it in:
With this setup, I should be able to quickly open the lid and connect the cables. At worst, I'll either set the case on the ground, make the charger quickly detachable, or use cable extensions to reach the bike inputs.
Anyway this seems like a good cheap way to use a charger with minimal wear and loading problems. And any improved charger should fit right in.
I'll update with further details shortly, including some CAD documents I made for layout.
