Insteon In-LineLinc Mount for 4" Square Electrical Junction Box

thingiverse

Insteon In-LineLinc Dimmers are ideal for controlling built-in lighting in my home, but their installation leaves much to be desired. The device must first be associated with another device (such as a light switch) using its SET button. However, once the device is installed in an electrical box, the button becomes inaccessible. The large size of the device also makes it difficult to get a sufficiently sized junction box. This bracket and cover are used to mount a 70x45x24mm In-LineLinc device in a 4" square electrical junction box. The cover features a window, allowing safe access to the buttons without opening the electrical box. The cover extends the box by 15mm, holding the device mostly outside of the original electrical box volume. This makes it easier to pack the electrical box. Materials Taulman Alloy 910 works well for these parts, holding self-tapping plastic screws securely in place. It is less flammable than ABS (UL 94 V2). Note that this cover will still be more flammable and have a lower melting temperature than a commercial UL-listed cover. 4" electrical box 8 screws: 6-19 x 0.500" or M3.63 x 12mm Pan Head Thread Forming Screw for Plastics, available at McMaster (99512A259 or 99397A682). Tools Drill Torx T15 driver. A right-angle ratcheting driver with a T15 tip is useful depending on how the electrical box is mounted. 1/8" drill bit 17/64" drill bit Instructions Measure the distance between the side mounting screw holes on your 4" box. Some boxes have 1.250", while others have 1.325", and some boxes feature both measurements. Print the correct device bracket and faceplate. Drill the eight pilot holes of the bracket with a 1/8" bit, then clean out any necessary screw head clearance hole on the faceplate using a 17/64" drill bit. Mount the electrical box so that the side mount holes are accessible. Complete all wiring within the electrical box, including the Insteon device. Slide the Insteon device through the opening of the bracket. Secure the bracket to the electrical box using four screws. Position the device within the bracket and place the faceplate in position. Use four screws to secure the faceplate to the bracket.