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HowTo: SSR Enclosure using extension cords
( Bill Adelsberger)
Step 5 : Mount the base and add wires
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| | Hold the SSR circuit against the wooden blocks and mark the opening in the base that is needed for the RJ45 jack. Cut the opening using a chisel or drill a hole and file the hole square. Mount the PCB to the wooden blocks using two small wood screws, as seen in the picture.
Cut off the male plugs from the ends of three 6 foot extension cords and cut one 12 foot extension cord in half. Note: I like to use 6 foot cords because a local discount store sells them for $.79 each, although longer lengths would be handy at times.
Pass two of the cords with the female plugs through the left outside hole and tie an electricians knot in each cord to keep the wire from slipping through the hole. Repeat this for the hole on the right side. Pass the cord with the male plug through the center hole and tie a knot in this one as well.
Cut the wires to a length that allows each wire to be connected to the PCB without any strain on the wire or circuit board. Lightly tin the wires with solder and connect one wire from each cord to the proper PCB connector.
Trim the remaining five wires to a shorter length, tin, and twist them together using an electrical wire nut.
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