ABI 24V 500W Power Supply Terminal Cover Plate

thingiverse

I purchased this power supply: ABI 24V 500W Power Supply Indoor Outdoor LED Driver Rainproof Weatherproof 21A https://www.amazon.com/ABI-Supply-Outdoor-Rainproof-Weatherproof/dp/B01IU8QBCO/ref=lp_17579358011_1_16?srs=17579358011&ie=UTF8&qid=1531079981&sr=8-16 I needed a terminal cover with a power plug, on/off switch, and 3 XT60 connectors. Since I couldn't find one on Thingiverse for this PSU, I designed one in Fusion 360. I used HONGYETAJA Inlet Male Power Socket with Fuse Switch 10A 250V 3 Pin IEC320 C14 https://www.amazon.com/gp/product/B01LYMNQ2L/ref=oh_aui_search_detailpage?ie=UTF8&psc=1 Fusion file is available below. You can view and download it. https://a360.co/2m0SdDr Printing ====== * I used Prusa I3 MK3. * AMZ3D PLA - neon-yellow. * 0.3mm Layer height. * Three top and bottom layers. * Three perimeter lines. * No supports. * 25% infill. * 210c nozzle and 60c bed. Assembly ======== I used 16 gauge wire on the XT60 connectors, as they can carry up to 24 amps of current. I soldered the wires onto the sockets and added heat-shrink before gluing them to the cover. The photos show 24 gauge wire on the 120V side of the socket. I should have used a thicker wire like 18 or 16. I used Gorilla Glue to attach the XT60 connectors and the socket to the PLA. I tried super glue but it broke after a few insertions/removals. The Gorilla glue is an expanding glue, so only use a little. I used a hobby knife to scrape off excess glue before it hardened. On the power supply, remove the 4 screws that hold the metal plate over the terminal strip. Remove the plate and put the cover over the end of the supply. Use the same 4 screws to attach them together. Improvements =========== * I should have used thicker gauge wire on the 120V side. 18 or 16 AWG wire would be better. * Perhaps the socket should have been rotated 180 degrees, putting the switch on the outside and the C14 plug on the inside. Credits ====== I was inspired by beefinator's Cover Plate for this design, which I used to get the dimensions of the XT60 hole.