1" Diameter Sheetmetal Cutout Split Plugs for cables

So… This is an odd one with a bunch of variants. It seemed like a simple task - make a cover plate for a security camera and pass the cable through the plate. Oh, and seal the cable tightly so that water does not get inside the box since the box is being mounted outdoors.

After making the cover plates, I discovered that there seems to be a rather lack of 1" plugs… Everyone seems to have plenty of 7/8" and 1-1/16" plugs available… (I wonder why? I guess if I would have thought a little harder about electrical fitting sizes before spinning up the cnc mill, I probably could have saved myself some additional work.)

Behold the solutions: A couple different plugs designed to fit a 1" diameter hole in a 0.040" thick metal cover plate with a CAT6, unshielded cable passing through.

Recommended to print in TPU or your choice of flexible materials. (I used TPU-95A with 3 wall layers & 30% infill.)

Files:

  ‘Solid Plug’ - a simple, solid plug to plug the hole in the cover plates until the cameras actually arrive.

  ‘Solid Plug - Innie’ - a plug that doesn't quite print as nice (supports needed), but was supposed to use less filament. 

  'Solid Plug - Outie' - a plug to fill the hole that uses less filament and prints nicer (3rd and final revision - use this one or the first one!)

  ‘Seal Plug - B’ - my second design on a cable pass through plug. My first was a simple hole and slot in the ‘outie’ plug. This one has a couple steps for different size wires - 6, 7 & 8mm wire.

  ‘Seal Plug’ & ‘Plug Plug’ - Final design that seems pretty robust. Insert cable and ‘Seal Plug’ in hole. Then grease ‘Plug Plug’ and insert it inside the ‘Seal Plug’. (it gets pretty tight!) Designed for 5.5mm wire - you can probably use 6mm, but that will get even tighter!