Sonoff Basic R2 wall box - Decora

thingiverse

I really liked what Old-Steve had done here with the SonOff basic wall j-box mount. It is fantastic in every way. Great engineering, makes use of existing SonOff screws, clean design and so on. But SonOff changes the design of the Basic over time. When I bought, all of mine were the Basic R2 V1.3. I noticed that there is a small problem with the housing. Steve's original design is expecting a 1.8mm thick PCB. But the new Basic R2 has a 1.1mm PCB. Only .7mm, but this small amount of slop is enough that when the board is seated in the housing, the pushbutton may be just far enough back that doesn't make contact with the spring button mechanism in the housing. You could put some foam or something to compress the board against the housing cover. But instead I decided to add small .7 mm fillers underneath the existing ones to accommodate the thinner PCBs. Also be aware that for the Housing, you need might need to scale it in your slicer to get it to the exact dimensions. The correct dimensions should put Y at about 106.6mm. For my printer that is 102%. The key is to make sure that on the printed housing, the Decora wallplate mounting screw holes are exactly 96.5mm or 3.80 inches apart. I printed using PETG as it is flexible and reasonably high temp. I also include a new paddle design. I noticed that most Deocra wall plates have a true 2mm radius in each corner. Steve's Decora paddle design isn't quite truly rounded but tapers a bit. I prefer the true radius to match the wall plates, so I redesigned the paddle. Also, I included two paddle options. 2mm thick so it sits flush with the wallplate per Steve's original design, and 4mm paddle so there is a 2mm relief above the wallplate. I prefer this design because then it makes it easier to find the button with one's fingers without looking and also looks more like other Decora paddle designs. And I put a bore directly over the Sonoff Basic LED location most of the way through the paddle. So if you want the LED to shine through, you can orient the paddle with the bore over the LED, or if not, just rotate it 180 degrees. Another thing I noticed is that Steve's design does not fit in to some "old-work" electrical junction boxes without pinching the input and output wires coming out of the top and bottom of the housing. So I modified the cover design as well to include holes for the wires to come out the back of the cover. And while I was at it, I added some embossing to note Line and Neutral and In and Out terminals. I've included the new design with and without the holes depending where you want the wires to come out. Lastly, I am using a small amount of XTC-3D epoxy to coat the paddle. This makes for a smooth glossy surface which matches many Decora wallplates and eliminates the bottom (print face down) layer lines. I printed using .25 mm nozzle to get the lines as small as possible to begin with and the paddle front side down on the print bed. I think the result looks great. Old-Steve nailed it though. With this design, it's possible to really democratize Home Automation. For just about $6 per device + a few cents in filament, you can convert every switch in your house to automated. And they will look as nice as the Leviton and other branded outlets costing $50 or more each.