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One-Off Inserts

by wizofwires, published

One-Off Inserts by wizofwires Nov 19, 2012

Description

Printable inserts to fit wall and floor box plates. Starting off with serial/monitor DB connectors. Heavy DB is a clip-in fitted for 4, 6 or 8 port wall plates. Narrow DB is a recessed clip in for 4 or 6 port floor box covers. Both layouts provide flush insertion depth and are intended for solder on connectors. This design requires the insert to be slid over the wire then soldering can be accomplished before clicking the insert into the plate. See instructions for details and links.

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Instructions

For A/V and IT applications,  many installations do not provide sufficient space in the wall-box or floor-box for the use of straight-through or shred adapters.  I have found solder-on connectors, with lash-wires for the shields to be a sturdy solution.  So I'll start off with DB9s and DB15HDs, but I plan to add more "one-off" inserts as I come up with the layouts.

For these two, either DB9 or DB15 require the insert to be placed over the wire first, before soldering the connector in place, then clicking the insert into the plate from the back-side.  For the "heavy" version intended for wall plates, I purchased a 4-port and dremel-cut straight across two horizontal ports, leaving the latching structure as-is.  The insert floats in the plate nicely but stays secure. The two vertical holes are chased with

a 4-40 tap and stand-offs hold the connector in place. I put some dust-cover files up with a handy tie clip. I also widened the "heavy" version slightly to use the dust-caps.

The connectors are available from "the shack"  (276-1501/1502 or 276-1537/1538) or mouser.  Don't use PC-mount connectors or you'll struggle.  "Lash-wires"  are simply stranded wire stringers that you loop back into the ground pins, they add strain relief.

I used Slic3r at .5 nozzle/.4 layer/.5 infill and got a very sturdy result (no-support/no-cooling).  I did do a quick search and didn't see any other inserts being worked on...give me a heads-up if so.
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