XT90 Handle Cover Outlet Mount Connection Protector Box with cable clamp

thingiverse

Warning: I just discovered that hex nut spacings are too large for standard M3 nuts and slightly too small for M4! What fits but doesn't spin is M3 square nuts! First approach to a connection saver with cable clamp - mixing it up with the source. I've added a keyed version along with tactile 'polarity hints' (featuring rounded and squared edges). In the latest update, grip features have been added to the handle as well as teeth to secure the cable (additional hot glue or silicone may be required depending on your cable usage). The key feature offers two distinct benefits: - If you print two identical sets, you'll have both sides with male and female connections that fit together perfectly - and only one way. - If you print each side along with a 'mirror part' of each side (included .3mf file), you can create one side with the square pin (XT90 male) and the other side with the round pin (XT90 female). The significance of the key feature becomes apparent when batteries (or other power sources) are connected in parallel - even close proximity to incorrect contacts must be avoided at all costs! I learned this lesson firsthand when I accidentally connected my second redundant battery connector (an XT60 back then) incorrectly, causing a plasma discharge. The bulkier handle combined with the key feature serves to protect the cable and its solder joint from the connector, allowing for a more secure connection since the outer case of the male connector disappears inside the female connectors' handle. I prefer printing these in PETG because it yields precise, sturdy results with reduced heat sensitivity compared to PLA... If you're interested in following my endeavors and contributing to clean solar-powered electric mobility, please visit: https://www.patreon.com/SunTripToGo This particular solution is now available on Ebay, complete with connectors and screws: https://www.ebay.de/itm/183816967377