Sonoff Dual R2 and POW R2 enclosure

This is an enclosure I made to make the Sonoff Dual R2 a little safer.

I'm using the Sonoff Dual to switch power to my 3D printer. The second outlet will be used in the future for controlling a low power heater in a dry box.

The cable glands provide strain relief for cables as well as keeping prying fingers out. Also the case is screwed together to further improve the kids safety factor.

There are flanges on the side to allow screwing down the case. They are sized for 4 gauge 8mm wood screws. I've screwed mine down to the underside of an Ikea Lack table.

---==== 12/12/2019 Update ====--- This case fits the Sonoff POW R2 as well.

---==== DON'T FORGET to join the earth wires!!!! ====---

Thanks to SuperHouse for giving me the idea ( https://www.superhouse.tv/21-six-sonoff-secrets/ )

Hardware:

- M3 5x5mm brass inserts ( https://rover.ebay.com/rover/1/705-53470-19255-0/1?icep_id=114&ipn=icep&toolid=20004&campid=5338495410&mpre=https%3A%2F%2Fwww.ebay.com.au%2Fitm%2FM3x5mmx5mm-Female-Threaded-Brass-Knurled-Insert-Embedded-Nuts-20pcs-K5G7%2F283061660972%3FssPageName%3DSTRK%253AMEBIDX%253AIT%26_trksid%3Dp2057872.m2749.l2649 )

- M3 8mm countersunk screws ( https://rover.ebay.com/rover/1/705-53470-19255-0/1?icep_id=114&ipn=icep&toolid=20004&campid=5338495410&mpre=https%3A%2F%2Fwww.ebay.com.au%2Fitm%2FM3-M4-316-A4-STAINLESS-COUNTERSUNK-FLAT-HEAD-SOCKET-CAP-SCREW-ALLEN-BOLT-DIN7991%2F322101148688%3Fhash%3Ditem4afeb97c10%3Am%3Am76okcRrd5Hqbx6G2IIKRKA%26frcectupt%3Dtrue )

- 12mm cable glands ( https://rover.ebay.com/rover/1/705-53470-19255-0/1?icep_id=114&ipn=icep&toolid=20004&campid=5338495410&mpre=https%3A%2F%2Fwww.ebay.com.au%2Fitm%2F5Pcs-12mm-Compression-Cable-Glands-Waterproof-Black-White-IP68-M12-TRS-Gland%2F382558205720%3FssPageName%3DSTRK%253AMEBIDX%253AIT%26var%3D651314538350%26_trksid%3Dp2057872.m2748.l2649 )

- Wire screw connector ( https://rover.ebay.com/rover/1/705-53470-19255-0/1?icep_id=114&ipn=icep&toolid=20004&campid=5338495410&mpre=https%3A%2F%2Fwww.ebay.com.au%2Fitm%2FSingle-Screw-Connectors-For-junction-box-wire-cable-joiners-32A-Bag-OF-10%2F263866171204%3Fhash%3Ditem3d6fa63f44%3Ag%3A-cEAAOSwvg9XUrO9 )

- Sonoff Dual R2 ( https://rover.ebay.com/rover/1/705-53470-19255-0/1?icep_id=114&ipn=icep&toolid=20004&campid=5338495410&mpre=https%3A%2F%2Fwww.ebay.com.au%2Fitm%2FSonoff-Dual-R2-WiFi-Wireless-Automation-16A-Smart-Switch-Module-Remote-Control%2F132598486193%3Fhash%3Ditem1edf7c54b1%3Ag%3Ad9QAAOSwPuRcDywc%26frcectupt%3Dtrue ) Print Settings

Printer Brand:

Prusa

Printer:

i3 MK3

Rafts:

No

Supports:

No

Resolution:

.15

Infill:

20%

Filament: Hobbyking PLA GreyPost-Printing

The hole sizes for the brass inserts are 5mm which is an interference fit on my Prusa i3 Mk3. I was able to tap the brass inserts into the holes with a hammer. rnrnYou can use a soldering iron to melt the inserts if required. rnrnYou can reuse the PCB screws from the Sonoff dual case to screw the Sonoff into the new mounting points.rnrnMake sure that you strip a generous amount of the outer sheating. I stripped approx 7cm. I nicked the wire insulation while stripping the outer sheathing, so I use some green heat shrink over the inner wires just in case. rnrn

How I Designed This

Category: Electronics