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HowTo: SSR Enclosure using extension cords
( Bill Adelsberger)
Step 2 : Prepare the enclosure
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| | The Carlon box show on the left has a few advantages over the inexpensive interior blue plastic boxes that one can often find for less than $.50. First there are no interior obstructions that are intended to secure wires or to mount plugs or switches. Second the sides are square and there are no angled recessed areas for the wiring. The square sides help to simplify the steps needed to make the box weather resistant. Lastly the box is a bit stronger due to the type of plastic used and a thicker wall construction. Unfortunately these advantages will cost you a bit more, around $1.40.
To prepare the boxes:
a. Cut off the outside mounting tabs and remove the nubs used for the face plate screws. The box on the left is before alterations and the one in the middle is after the changes.
b. Sand the sides relatively smooth. A belt sander works well if you have one.
c. Wrap the sides and bottom with water proof duct tape, as show on the box on the right. I used 2 inch black "Gorilla Tape" but there other manufactures who sell similar products. The tape that I used was only available in a two inch width. To cover the box required two strips of tape for the sides plus a piece for the top.
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