Cutting bodywork

[thedogsbollox]

I have to fit a 240v flush fitting inlet socket. What is the best method so as not to c**k it right up. I am thinking drill a load of holes and cut between with a junior hacksaw then file smooth. Possibly paint over the bare metal?

[dave_aber]

If you have no option but to cut the bodywork, then a chain of holes is a good bet. You need to avoid denting the surface as you drill, so go easy. I had a look at these flush fitting mains inlets for my rear bumper - some of them need a huge space inside, so make sure you are not going to bump into anything in there. Definitely paint over the raw metalwork once you have cut it, otherwise you will have plenty of rust. The hole should be a fair bit smaller than the overall size of the inlet's lid, so you shouldn't have to match the paint, just get the metal covered.

Is there no way you can mount the inlet on a towbar and feed the cable inside?

[thedogsbollox]

If you have no option but to cut the bodywork, then a chain of holes is a good bet. You need to avoid denting the surface as you drill, so go easy. I had a look at these flush fitting mains inlets for my rear bumper - some of them need a huge space inside, so make sure you are not going to bump into anything in there. Definitely paint over the raw metalwork once you have cut it, otherwise you will have plenty of rust. The hole should be a fair bit smaller than the overall size of the inlet's lid, so you shouldn't have to match the paint, just get the metal covered.

Is there no way you can mount the inlet on a towbar and feed the cable inside?

Still in 2 minds about flush mounting on the outside but like the ease of use. I have other options but will have to check them out. If I have to do it then I will defo make sure the socket fits on the inside before drilling.

[dandemann8]

This is how I decided to install a 240v hook up, it saved me cutting the panel and it work's very well

http://www.igmaynard.co.uk/bongo/forum/ ... +electrics

[Scott]

I am going to fit an outlet into the rear passenger panel of the bus, for the awning electrics.

step 1 - measure
step 2 - measure
step 3 - measure
step 4 - drill pilot hole
step 5 - measure
step 6 - pray
step 7 - measure
step 8 - drill the other 3 corners
step 9 - jigsaw out whilst praying
step 10 - seal exposed metalwork with hammerite

then shove it socket and wire up

[dave_aber]

This is my inlet, attached to the end of the towbar on the right hand end. Sorry i've not got a closer photo to hand. Looks like the same inlet that dandemann8 has used. Mounted on a bit of plywood to space it out from the towbar end plate. Socket is waterproof, so should be OK with the wheel spray (so I'm told....)

[thedogsbollox]

Have you found a flush fitting outlet as the normal ones will look real ugly.

[jaybeeonline]

Mine went into the rear bumper, saving me cutting metal and creating exposure to the dreaded tin worm.

http://www.igmaynard.co.uk/bongo/forum/ ... 47&t=39582


J.

[haydn callow]

I used a angle grinder...dead easy and very neat.

[321Away]

The boys at 321, cover the area with several layers of masking tape, mark with template, drill a big 10mm hole, then have a 'soft foot' for the jigsaw which even without the tape wont mark paintwork, after its been cut out all edges are painted in red oxide paint.
Julian

[Scott]

Have you found a flush fitting outlet as the normal ones will look real ugly.

Ebay outlet linky

[haydn callow]

Thats a outlet socket........he's fitting a inlet socket

[Scott]

Thats a outlet socket........he's fitting a inlet socket

Have you found a flush fitting outlet as the normal ones will look real ugly.

Ebay outlet linky

[haydn callow]

I have to fit a 240v flush fitting inlet socket. What is the best method so as not to c**k it right up. I am thinking drill a load of holes and cut between with a junior hacksaw then file smooth. Possibly paint over the bare metal?

[Scott]

I have to fit a 240v flush fitting inlet socket. What is the best method so as not to c**k it right up. I am thinking drill a load of holes and cut between with a junior hacksaw then file smooth. Possibly paint over the bare metal?

He asked me if I had found an outlet socket that wasnt the ugly blue outlet on a box and I answered, regardless of inlet or outlet box, that style has the same dimensions, so the cut out would be the same.

Inlet

outlet


In my opinion this outlet is better looking than