Mounting plate with seal e.g. for cavity wall boxes

🔧 Mounting Plate for Exterior Wall (Cavity Wall Boxes) – with Seal & Variants

Not every wall is perfect:
oversized drill holes, broken plaster or oversized cavity wall boxes often make mounting outdoor lights unnecessarily difficult.

This mounting plate was developed precisely for such cases (originally, as always, because I myself had the corresponding need – but then designed so that variants can be created quickly, some of which I am uploading here in the various profiles).

It ensures stable fastening, a clean finish, and sealing – especially with problematic wall openings.

✨ Features

• Large contact surface
  Reliably covers even greatly enlarged or untidy openings (up to ~130 mm)
• Central cable pass-through (30 × 30 mm)
  Offers sufficient space for cables, terminals, or routing multiple cables
• Integrated TPU seal
  Adapts to rough plaster and slight unevenness within limits
  → protects against moisture and ensures a clean finish
• Stable wall mounting outside the box
  Fastening is deliberately done in the load-bearing wall area, not in the plaster or box cutout
• Additional stabilization for plastered insulation (ETICS)
  The large contact surface distributes forces better and prevents sinking or breaking out in the plaster
  → ideal for insulated facades
• Optimized for ASA printing
  UV-resistant, temperature-stable and durable for outdoor use

📏 Variants

🔩 By Cavity Wall Box Size

Versions with optimized wall drillings (with sufficient distance to the opening):

• 80 mm
• 90 mm
• 100 mm
• 130 mm

👉 The drill holes are positioned such that secure screwing into the wall is possible

💡 By Purpose

🟢 Device-specific Variant

• Suitable for:
  Oktaplex Cali Dos LED outdoor spotlight (motion detector)
• M4 Through-holes
• Integrated hexagon recesses for nuts
  → easy assembly without counter-holding

👉 Ideal for quick and clean installation of this light

⚪ Universal Variant

• Without additional drillings
• flexibly usable:
  • make your own drillings
  • use screws directly
  • suitable for various outdoor lights

🧰 Assembly

1. if necessary, mount lamp base on the mounting plate
2. Align mounting plate on the wall
3. Fasten through the designated drillings outside the box
4. Seal automatically fits cleanly against the wall
5. Mount light (depending on variant)

🧪 Material Recommendation

• Plate: ASA
  → weatherproof, UV-resistant, temperature-stable
• Seal: TPU 90A
  → flexible, reliably seals even on rough surfaces

💡 Adjustments

The model is deliberately designed so that it can be easily adjusted:

• other dimensions
• individual hole patterns for lamp bases
• special on-site requirements

👉 Adjustments can be made directly in the shared Onshape document or simply contact me – I'll be happy to help.

💡 Practical Tips

• Ideal for:
  • broken plaster
  • oversized drillings
  • insulated facades (ETICS)
  • visible box cutouts
• The seal is designed to
  compensate for unevenness without requiring excessive contact pressure
• For optimal print quality:
  • use an enclosed build chamber
  • print slowly
  • use a brim for large parts
  • if you know your printer and material, you can of course greatly increase the print speed

🎯 Goal

A simple solution for a common problem:
stable mounting + clean appearance + reliable sealing
– even when the wall is not perfect.

Have fun printing & assembling! 🚀