Hummer H3 Power Station

thingiverse

This was a custom design for a coworker who owns a 2008 Hummer H3. She handed me a Bell Power Station ($14 on Amazon)... http://www.amazon.com/Bell-Automotive-22-1-39275-8-Station-Holder/dp/B008QBTV4G/ ...and asked if I could re-design it to fit into an otherwise useless pocket near her dash. This turned out to be a significant challenge due to the space constraints, but I managed to accomplish it. The circuit board for the USB ports was a major real estate hog and left little room for the two cigarette ports. But enough of my complaining. The good news is that now that it is designed, the printing and assembly is relatively easy (assuming you can solder and have a basic understanding of electricity). See the "Instructions" tab for details. Instructions Print one of each part. You will want to use ABS or PETG plastic materials. PLA plastic will melt and shrink in the heat of a car's interior. I'd also recommend printing them mostly solid. The bracket might require support, but the others do not. You will want to get a high-quality first layer for the faceplate, as that will be the only thing visible. Now follow these steps: 1) Take apart the Bell Power Station - save the screws and the chrome plastic bezels. 2) Unsolder the power cord and two cigarette ports. Leave the wires coming from the USB board intact. 3) Insert the two chrome rings/bezels for the cigarette ports. Pay attention to the notch. You may need to file the holes slightly to get them to fit. You can also remove a little plastic from the rim around the closest USB hole. No worries are required. 4) Now install the bezels for the USB Ports. Some filing may be necessary once again. 5) Lay the faceplate face-down on a soft cloth. Place the two cigarette ports in place on top of the bezels. Pay attention to the notches again. 6) Secure the cigarette ports with the bracket and four of the screws that you saved. If the bracket does not seem to hold tightly enough, snip/trim/file a bit off of the four mounting posts. Do not over-tighten the screws. 7) Attach the USB circuit board with two more screws. No need to get too crazy while tightening these. A snug fit will do. 8) Use super glue to attach the power cord in place. You will have to trim off some rubber to get it to fit into the hole. Superglue should hold well if you printed in ABS plastic material. 9) Wire everything up. The USB board and the two Cigarette ports need access to the 12V coming in from the power cord. How you accomplish this is up to you. Just remember that the outside of the power ports are negative (black) and the centers are positive (red). If this confuses you, stop now and ask for help before you cause any damage. 10) Glue on the walls with superglue. I know this might seem a bit lame. However, the walls are not subjected to any stress when in place, other than compressive forces, so I do not feel too embarrassed about this. 11) Optionally line the outside with felt or rubber for a nice fit and prevention of rattling. You would likely not hear it anyway, given that your car is a Hummer. It's up to you to decide. 12) Profit!