PORTABLE DIESEL HEATER STATION
Technology Meets Excavation
TOTAL BUILD: $1,047.35
Technology Meets Excavation
Construction crews in mountain winter need reliable, portable heat
Winter jobsites in the Truckee, CA mountains drop below freezing—sometimes well below zero. Construction crews need reliable heat, but traditional propane heaters are dangerous in enclosed spaces, heavy to move, and require constant fuel management.
This portable diesel heater station solves that problem. It's a self-contained system that runs on battery power, produces clean heat, and operates for 20+ hours on a single charge. The heater mounts inside a weatherproof steel enclosure with a dedicated LiFePO4 battery system, quick-disconnect charging, and sealed ducting to direct warm air where it's needed.
Built by Errol Kerr (E Kerr LLC / Ruppert Excavation), this system is battle-tested on real construction sites and proven to work in extreme cold.
Bottom line: 20+ hours of heat, portable, efficient, and tough. All for under $1,100 in parts.
HCALORY TB-MAX Battery Sizing & Performance Data
Real photos of every phase — from heater unit to complete system
HCALORY TB-MAX specifications and performance data
Intake, exhaust, and electrical connection points
Complete HCALORY TB-MAX diesel heater assembly
Main enclosure mounted on sawhorses for initial setup
Steel tongue box structural assembly
Heater mounted inside with cables and ductwork
Mounting and connection details
Heater box with yellow flexible ducting installed
Complete enclosure ready for integration
LiFePO4 battery system with voltage monitor (13.3V, 100%)
Anderson connectors and electrical distribution
Professional wiring and fuse protection
Orange weatherproof case for portable charging system
Charging cables and connectors organized inside case
Battery box connected to charger with Anderson quick-disconnect
Heater unit, battery box, and charger system together
All three major components integrated and ready
How the heater, battery, and charger fit together
Complete portable heater station ready for deployment
All systems integrated and tested
Ready for real-world jobsite deployment
Everything you need, with direct Amazon affiliate links
Step-by-step assembly and commissioning guide
Start with the Haul Master Steel Trailer Tongue Box (ASIN B0842VHDVQ). Carefully drill intake and exhaust vent holes to specifications (typically 4-6 inch diameter for adequate airflow). Mount the HCALORY TB-MAX heater unit securely inside the case using vibration-dampening mounts or rubber isolators. This prevents vibration transfer and extends component life. Test fit all connections before final assembly.
Install the dual WannaPow 120Ah LiFePO4 batteries in a secure enclosure (separate battery box or dedicated section). Wire them in parallel configuration to achieve 240Ah at 12V. Connect the Anderson 50A panel mount connector as the primary distribution point. Install a voltage meter for real-time battery monitoring. Add a master kill switch for safety. All connections should be crimped and soldered—no loose connections. This is the most critical electrical step.
Run 8AWG cables from the battery Anderson connector to the heater unit (typically 15-25 feet depending on layout). Install an inline fuse holder (50A rated) within 18 inches of the battery positive terminal. Use proper cable sizing tables for your cable run length. Wire connections must be crimped with a professional crimper—soldering alone is insufficient for high-current applications. Anderson quick-disconnects on the heater end allow safe field disconnection for battery swaps.
Attach the dryer vent coupling to the heater exhaust port. Run flexible insulated hose from the heater through the enclosure vent hole to direct hot air where needed. Use hose clamps every 12-18 inches to prevent kinks and maintain airflow. Install duct vents on the enclosure to prevent pressure buildup. Test airflow by running the heater briefly with the enclosure sealed—you should feel warm air exiting the ductwork within 30 seconds.
Apply weatherproof sealant (marine-grade silicone or polyurethane) to all external seams and connection points. Install the heavy-duty 9.5x12 tarp over the main heater unit, securing with bungee cords or rope. Cover the battery enclosure with the 8x10 canvas tarp. Ensure the main exhaust duct opening is not blocked. Use pop rivets to secure any tarp flaps permanently. The goal is water-tight sealing while maintaining necessary ventilation.
Before deployment, perform a full test run. Check the voltage meter reads 13.0V+ at rest. Start the heater and monitor current draw (should be 1-4A continuous after startup). Let it run for at least 30 minutes while monitoring voltage to ensure it doesn't sag below 12.0V. Check all connections for warmth (indicating resistance losses). Verify exhaust ductwork produces hot air. Perform a 2-hour runtime test to confirm system stability. Document all readings. You're now ready for jobsite deployment.
Real-world performance metrics from deployed systems
Continuous heat on a single battery charge. Verified under load at full power draw.
Tested in extreme Truckee mountain winter conditions. Heats through the coldest nights.
Fits in any standard truck bed. Easy to tow, park, and deploy on jobsite in minutes.
Anderson quick-disconnects allow battery swaps in under 2 minutes. Keep heater running while rotating fresh batteries.
Complete system including batteries and all electrical. Professional quality at DIY cost.
No proprietary parts. All components available on Amazon or at local hardware stores.
All the parts are just a click away. Use the links above to source components on Amazon with our affiliate tag. Every purchase supports KERR MARKETPLACE.
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