No volts released!

A criminal stole a handbag, was chased and caught, and was asked to take part in an identity line up. When the woman victim appeared, he immediately pointed and said “That’s her! That’s who’s handbag I stole!”...

I need to put an emergency stop switch in place in case my blouse get’s caught up in something spinney.

With The Base on it’s Maple Feet, it’s working position, I made a mark where my left knee contacts…

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…It’s the black dot. Here’s the No Volt Release (NVR) switch…

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You can see there’s substantial bulk behind the front black casing. I thought I’d just measure it and cut out a rectangle from the front of The Base for it to sink into. Two problems arose with that idea. One is this..

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…the shelf structure. Very difficult to cut into; a lot of work. Just move the NVR switch up or down? My knee won’t connect ideally then. The other problem is that the connections won’t be protected and the double thickness of wall metal might mean those connections would be troublesome.

The solution is this…

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…a protective box. First I made a card template…

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…and transferred the shape to the front casing of the box…

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…and cut it out…

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The cutout is displaced to the south to allow room for connections and cable inside. I cleaned up the edges with files to get the best fit. I drilled holes for the fixing bolts. This is the result…

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Inside the box itself, I drilled out a 20mm hole to let the cables in and also a small sight hole just south of centre. This aligns with the centre of the red button and is for easy lining up with the black dot on The Base. I drilled out the fixing holes.

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The box was then aligned onto The Base casing, marked up and holes drilled with the 6mm bit to start and the stepped bit to finish. The big 20mm hole took a bit of effort with the hand drill. Trying not to press too hard and taking it steady worked. You can see that now all the holes miss the shelf structure…

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The box is then bolted on, the NVR switch fitted to the casing and this is the finished article…

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Inside the NVR switch…

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It has spade terminals for connections…

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…and came with a highly detailed comprehensive wiring diagram…

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If it works, it’ll do.

Next, connections…

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