1590B.Jack.Washer.2a

thingiverse

Hello, I'd like to share my technique for top-mounting jacks on 1590B enclosures that doesn't require expert measuring or plotting skills, but instead uses an inner washer to clear the jacks from the lid's lip when closed. The problem I initially encountered with top-mounting jacks was their tight fit against the inner nut of the 9v jack. Without proper drilling, I experienced issues like this: [img]https://i.imgur.com/2lmNRMT.jpg[/img] I was pinching the 9v nut with the output jack. Even if I spaced the jacks enough to clear each other, I still faced problems like this: [img]https://i.imgur.com/czFampR.jpg[/img] The lid wouldn't shut all the way. At first, I thought about grinding down the lip to solve the issue, but that wasn't a fun solution. So, I kept thinking and came up with a better approach: [img]https://i.imgur.com/QXN00K7.jpg[/img] These small washers not only allow the 1/4" jacks to clear the lid & the 9v nut, but also position their outer edge flush with their washers and nuts: [img]https://i.imgur.com/ppX4Sx7.jpg[/img] 3D printed washer Since I have a 3D printer, I print my own washers. However, for this report, I've bent heavy wire to demonstrate an alternative solution that works equally well: [img]https://i.imgur.com/OUxn6eE.jpg[/img] Wire washer Here's the key benefit of using these washers: [img]https://i.imgur.com/U13BhjH.jpg[/img] A nice closed lid. If you struggle with top-mounted jacks, I recommend trying this method. I'll soon share an STL file for those interested in printing my design. I'd love to hear about your own methods for dealing with this issue - if anyone has a better solution, please share it! Thanks for reading.