Step 1 : Punch out knockouts in 4 square box


This HowTo Requires the following supplies:

1 – Metal 4” Square box (deep preferred)
1 – Dual duplex receptacle 4” square box cover.
1 – Piece of aluminum angle.
2 – Duplex receptacles.
1 – Fuse holder.
1 – IEC Connector.
1 – SSR board with isolated triac's.

Misc. supplies including wire, crimp connectors, bolts, nuts, ect.

My costs for a complete setup, including SSR board, and power cord was $16.07

The first step involves removing the 3/4" knockout on the side as well as the 1/2" knockout in the center on the opposite side.

Step 2 : Mount IEC connector and Fuse Holder


Using a drill bit drill a hole in the 1/2 “ knockout next to the 3/4 “ opening you made in the previous step. The drill bit should be large enough to accommodate the fuse holder you are installing.
After the hole is drilled install the IEC connector into the 3/4 “ knockout you removed in step #1 with my box and IEC connector all that was needed was firm pressure to press the connector into the hole.
Next mount the fuse holder into the hole you drilled and secure.

Step 3 : connect fuse holder to IEC connector.


Solder wires to the Fuse holder and connect the fuse holder to the IEC connector.

Step 4 : Assemble the SSR boards.


Assemble your SSR boards. The boards in the pictures are from the Corp Order with the fuse holder jumped and the Terminal blocks mounted on the reverse side. This allows easer hookup of the wires after the board is installed. the Triacs are isolated tab. this is required because I am hooking them upto the metal case.

Step 5 : Bend and drill your angle.


My angles measure 1.75” X 2.6” with the bend at 1”. I laid the angle up to the SSR’s and marked the holes. I drilled these holes and mounted it temporality to the SSR’s, I installed the SSR board into the Box and marked 2 holes to mount it with. I removed the angle from the board and drilled the remaining 2 holes. I then used this piece as a template for drilling future angles. The length of the second side (opposite the 1” side) is not critical, I am using scrap material so some of the lengths are different.