This is a case for the Sparkfun Beefcake relay. In addition to the two 3D printed parts, you will need:
Print the two parts in the orientation shown. The parts should not need support.
NOTE: This project involves working with high voltage. Please make sure you know what you are doing. This project should be reasonably safe, but if done wrong, these voltages can be lethal.
I included the Solidworks filed in case anyone wants to modify the design.
No supports needed. Material does not really matter.
- Print the two parts
- While the two parts are printing assemble the relay pcb. Note: Install the LED on the bottom side of the board. This is the opposite side from what the directions tell you to do. Make sure that the LED polarity is right when you do this.
- Install the eight heat set inserts in the eight holes in the bottom part.
- Screw the relay board into the bottom part using two of the socket head cap screws. The LED (which you installed on the bottom of the board) should fit through the hole in the bottom part. You may need to use a drill bit or a file to get the LED to fit.
- Cut the power cord where you want to put the relay.
- Strip the outer jacket off the power cord to expose the inner wires. Make sure to expose enough length, 2-3 inches will be plenty.
- Install the cord grips on the power cord, and install one side of the cord on either side of the bottom part.
- Solder the neutral (white) and earth (green) wires together after the cord grips are installed. These are not switched by the relay and will pass through the box.
- Attach the hot (black) wire to the relay board. I attached the inlet wire (from the wall) to the COM terminal, and the outlet wire to the NO terminal.
- Use the flexible hooks on the side of the bottom part to contain the high voltage wires. I recommend minimizing the amount of extra wire length so that everything fits in the box well.
- Install the grommet in the side hole and feed through the control cable. Attach the control cable wires to the screw terminal on the PCB.
- Put the top part on the bottom and attach with the other four socket head cap screws.
- Flip the part over. :P