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Submitted By:   jjewell@telus.net
Email List:   RV-List,Aeroelectric-List
Name:   

Jim Jewell

Date:   

Dec 17 2003

Subject:   Homemade Baffle Pass Through Fitting
Description:   

A wire pass through pictorial how to:

The attached photos will indicate how I chose to approach the task. The first few photos are the prototype that I fashioned out of 1/8th inch thick UHMW (Ultra High Molecular Weight) stock material.

I made another one out of Phenolic that is now in place and shown mounted in the last three pictures

Because I pre-drilled the holes in the baffle at a given spacing during an earlier idea try out, the unit when assembled is physically larger than need be. Moving the mounting screw holes closer together would allow a slight reduction in overall weight. However, using the wider spacing does allow a larger number and or variety of holes as needed.

I made the part that is now in use out of 3/16th inch Phenolic material. This adds a bit of extra weight but offers slightly better material support for the wires. I made the finished wire holes a loose fit for the wires and then wrapped the wires with a bit of silicone self bonding (cold vulcanizing) tape from B&C. I have also seen the same tape in local electronics shops. With the right (small) amount of tape wrapped around the wires the pieces all fit comfortably but snugly in place.

The cutting tools used were: A small table top scroll saw, A Dremel with a very thin diamond cut off wheel, a model builders Exacto blade for the Plastic version. and a Delta 30 inch belt sander. For the Phenolic material a hack saw also works well.

If further information is needed send email. jjewell(at)telus.net

Jim Jewell in Kelowna

 
    DSCF0104.jpg Photo 1
    DSCF0105.jpg Photo 2
    DSCF0106.jpg Photo 3
    DSCF0107.jpg Photo 4
    DSCF0108.jpg Photo 5
    DSCF0116.jpg Photo 6
    DSCF0117.jpg Photo 7
    DSCF0118.jpg Photo 8





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