Bosch eBike Charger Wallmount (added removable plug)

prusaprinters

<p>This print allows to elegantly mount your Bosch eBike Charger to the wall, out of the way, right where you need it.</p> <p>I made this version because several people indicated that they liked my <a href="https://www.prusaprinters.org/prints/53056-ebike-charging-station">eBike Charging Station</a> but preferred a standalone version of the wallmount, without the integrated power outlet.</p> <p>It does not have all the features of the original design, but has some benefits of its own: it is very compact, trivial to assemble, and faster to print.</p> <p>This model does not support the same level of cable management as the original, but the power cable can easily be routed upward (obviously), but also downward by routing it behind the charger, such that it can leave the wallmount at the bottom, next to the DC cable (see photo).</p> <p>It is specifically designed for the Bosch eBike Systems Standard Charger (4 ampere). It uses the same rails as the original design, so you can reuse the rails if you decide to upgrade to the full design later on.</p> <p>Note: There are now two plugs available:</p> <p><ul></ul></p> <p><li> Locking Plug: original plug, locks in place, but difficult to remove.</li></p> <p><li> Removable Plug: easily removed using tweezers or pliers.</li><br/> &lt;/ul&gt;<br/> You only have to print one of them. I recommend to try the Removable Plug first.</p> <p><br/><br/> <b>Change Log</b></p> <p>2020.02.13 Added removable plug as alternative to Locking Plug.</p> <h3>Print instructions</h3><p>I printed everything in PETG for maximal strength and flexibility.</p> <ol> <li><b>Left Rail</b> The left rail is laid on its side (biggest holes on print bed) to minimize supports and maximize the strength. Originally, I printed it parallel with the X axis, but the latest PrusaSlicer complains about toolpaths outside the print area. Therefore, I rotated it 45 degrees. Settings: <ul> <li>Print settings: 0.15 mm QUALITY to obtain the smoothest possible curves.</li> <li>Supports: Everywhere. They are certainly needed for the hooks and also the top holes.</li> <li>Perimeters: Increased to 15 to have no infill at all.</li> </ul> </li> <br/> <li><b>Right Rail</b> Same as Left Rail. </li> <br/> <li><b>Bottom Plate</b> The Bottom Plate is printed upside down to avoid supports. Settings: <ul> <li>Print settings: 0.20 mm QUALITY</li> <li>Supports: None.</li> <li>Perimeters: Increased to 4.</li> </ul> </li> <br/> <li><b>Removable Plug (recommended)</b> The Removable Plug is printed upside down to avoid supports. Settings: <ul> <li>Print settings: 0.20 mm QUALITY</li> <li>Supports: None.</li> <li>Perimeters: Increased to 4.</li> </ul> </li> <br/> <li><b>Locking Plug (consider Removable Plug as alternative)</b> The Locking Plug is printed upside down to avoid supports. Settings: <ul> <li>Print settings: 0.20 mm QUALITY</li> <li>Supports: None.</li> <li>Perimeters: Increased to 20 such that the top consists of concentric perimeters.</li> </ul> </li> <br/> </ol><p><b>Assembly and Installation Instructions</b></p> <ul> <li> Drill two holes in the wall, about 40 mm apart on a horizontal line.</li> <li> Attach the Bottom Plate to the wall with two screws (5 mm diameter).</li> <li> Make sure it is aligned vertically before fastening the screws completely.</li> <li> Slide the dove tails of the Left and Right Rail together.</li> <li> Put the hooks of the Rails inside the matching holes in the Bottom Plate.</li> <li> Slide the Rails down until the Plug hole in the Left Rail and the Bottom Plate are perfectly aligned.</li> <li> Verify that everything works as expected.</li> <li> Finally, if the Rails tend to slide upward if the charger is removed, insert either the Removable or Locking Plug in the hole of the Left Rail. The Removable Plug is the preferred solution as the Locking Plug is very difficult to remove, if needed. </li> </ul>