Voltex CPP4H Four-Gang Corrugated Backing Plate

Description

These models are part of the Corrugated Iron Collection

The Voltex CPP4H Four Gang Outlet Back Plate is designed to attach the outlet to a corrugated iron wall. 

Metal + 240V Electricity, what could possibly go wrong? Well a lot less if you use this backing plate :)

Since the outdoor sockets have a flat back mounting, if you are trying to mount a recessed switch or socket then I have a generic 120x120 mm square plate here - IronWave Switch - Corrugated Metal Switch Plate

Product Link

CPP4H - Four Gang Horizontal Power Outlet Double Pole 250V 10A
 

Design Considerations

Corrugated iron is an iconic Australian building material, but poses some challenges when using it on structures as vertical walls. This backplate is designed to be used with a twin socket outdoor power-socket. 

• Cabling Access - A single central penetration allows cabling to pass through to the back of the socket. Ample space has been provided to allow for inaccuracies in the penetration location.
• Socket fixings - All pilot holes to secure the socket to the backing plate are provided. Reinforced.  
• Wall fixings - Two holes, positioned above and below the center, accommodate metal roofing screws to attach the plate securely to the ridge of the corrugated iron. The recess keeps the head of the screw from fouling with the back of the socket. You can also use longer metal screws through the 4x Socket back plate holes then through my backplate into the wall.  
• What are the yellow cylinders for? - These modifiers instruct the slicer to generate 100% solid concentric infill at their intersection with the model. Don't worry, the yellow cylinders are not physically printed. The 100% infill enhances the strength around mounting points where screws are used. While the entire plate could be printed with 100% infill, this would result in unnecessary plastic waste. 

Corrugated iron is formed by rolling metal sheets through a series of rollers are designed with grooves that press the metal into the characteristic corrugated shape.  The process is not mm precise particularly in the vertical and there are many factors from the manufacturing, brand, design and installation that can make changes to the height in particular. You may find you need to scale either the height, width or both - if a perfect fit is needed. 

Corrugation Height Changes:
 

To measure the corrugation height, follow these steps:

1. Place a ruler flat across the corrugations.
2. Use a caliper's depth gauge to measure the distance to the base of the corrugation. Don't forget to subtract the thickness of the ruler.
3. Alternatively, you can use a second ruler to measure from the underside of the top ruler to the base.

The corrugation height for this model is 16 mm. To adjust the backplate for a different height, use the scaling formula below:

Scaling Formula:
 

( Desired Height ÷ 16 ) x 100 = Scaling Factor percent - Deselect ‘uniform scale’ to apply only to Z.
 

Example Calculation:

For a desired 17 mm height:
 

(17 mm ÷ 16 mm) x 100  = 106.25 - Z-axis scaling
 

Corrugation Width Changes (pitch):

Not recommended to change this if you are trying to fit the Voltex CPP4H Four Gang  outlet.

Material Choice for Printing

While PLA could work here - given metal conducts heat and this is an outdoor product, I would recommend PETG-HF, particularly if the area is in direct sunlight. You can try PLA if the location is under shade (verandah or inside a shed for example). I have selected a Black and White PETG HF in the Bill of Materials to match the colors the socket is sold in. The Gray is a good color if you are planning to paint the backplate.
 

Enjoy!