power panel questions/suggestions

[shade]

Polycarbonate is widely used in industry for similar purposes.
One cavaet
In industry strong consideration is made regarding its fire retardant properties. But as ’some guy’ rigging up a camper, the choice is easier.

Thanks for the advice. Time to start looking for a big enough piece of scrap to cut down.

I've burned polycarbonate before, and 1/4" takes a fair amount of trouble to sustain a flame. Once it does, I can see it creating a problem, but if it gets that hot inside my truck cab, a whole lot of other stuff will have already lit off. In an industrial setting, I can see it being a potential problem, though.

 

[dreadlocks]

I would much rather an electrical panel be an insulator than a conductor like OP here.. so as far as safety is concerned your already miles ahead in your design.

 

[blackohio]

I would much rather an electrical panel be an insulator than a conductor like OP here.. so as far as safety is concerned your already miles ahead in your design.

You musta been a ton of fun at parties.

 

[shade]

You musta been a ton of fun at parties.

Dude, he's rockin' dreads. He is the party.

As long as you install everything correctly - and I have no doubt that you will - your panel will work fine and look great. I was asking for myself because I'm still planning my system. I wasn't trying to get a dig in on your work.

 

[blackohio]

Dude, he's rockin' dreads. He is the party.

As long as you install everything correctly - and I have no doubt that you will - your panel will work fine and look great. I was asking for myself because I'm still planning my system. I wasn't trying to get a dig in on your work.

I never took your comments as digs at all.

 

[shade]

I never took your comments as digs at all.

Just wanted to make sure. It's so easy to let things go sideways through text. I've been hoovering up information from many sources, and when I see someone actually installing a system, I pay particular attention.

I don't know if you care to change the appearance of the panel, but I used a DA sander to put a uniform, satin finish on the aluminum front skid plate on my truck. I didn't care what the rest of the plates looked like, the the tool marks from the press brake on the front were a little rough. If you wanted, I'm sure you could sand and buff your panel to mirror finish, but I think a satin finish looks great, won't show grime, and it's easy to do.

 

[blackohio]

Just wanted to make sure. It's so easy to let things go sideways through text. I've been hoovering up information from many sources, and when I see someone actually installing a system, I pay particular attention.

I don't know if you care to change the appearance of the panel, but I used a DA sander to put a uniform, satin finish on the aluminum front skid plate on my truck. I didn't care what the rest of the plates looked like, the the tool marks from the press brake on the front were a little rough. If you wanted, I'm sure you could sand and buff your panel to mirror finish, but I think a satin finish looks great, won't show grime, and it's easy to do.

We have a full paint / powdercoat shop in the office. Dropped the panel off yesterday, matte black powder today. So, at least now much too mr. dirty hair's chagrin it is at least somewhat non-conductive now.

 

[shade]

Looks very nice. Now you can get to the fun part.

 

[blackohio]

Yup, was hoping to bolt all the ******** back up tonight, but we had to put our 14yo gsd down this morning and the wife took it hard

My stupid ass lab was like cool, all this room is mine now, solid.

 

[dreadlocks]

You musta been a ton of fun at parties.

 

[Alloy]

I've been meaning to ask, and since this is indirectly related to the topic, would 1/4" polycarbonate sheet work well for a large mounting surface on par with the OP's project? I've worked with it on other projects and been satisfied with its durability, it's easy to saw & drill, and it's non-conductive.

Polycarbonate may crack around the holes while drilling and around the mounting holes if there isn't room for thermal expansion.

Cracks may form around threaded fasteners

Chemicals including adhesive stickers will cause solvent stress cracking.

Easy to scratch.

 

[shade]

Polycarbonate may crack around the holes while drilling and around the mounting holes if there isn't room for thermal expansion.

Cracks may form around threaded fasteners

Chemicals including adhesive stickers will cause solvent stress cracking.

Easy to scratch.

Thanks for the observations.

I'll check on the expansion issue. I've used the same material bolted down outside and not had a problem with it, but I know some polymers are more prone to the problem than others. Polycarbonate degrades and becomes brittle under UV exposure, but that shouldn't be an issue for this use.

I won't apply anything to the polycarbonate, even paint. Scuffing it with a DA sander to a satin finish mitigates marring, at least well enough for me. Any labeling will be on the cables.

I also may add some cushioning between the sheet and the mounting rib on the back wall of my cab, so that may help with vibration related damage to the sheet and mounted components.

 

[Alloy]

Thanks for the observations.

I'll check on the expansion issue. I've used the same material bolted down outside and not had a problem with it, but I know some polymers are more prone to the problem than others. Polycarbonate degrades and becomes brittle under UV exposure, but that shouldn't be an issue for this use.

I won't apply anything to the polycarbonate, even paint. Scuffing it with a DA sander to a satin finish mitigates marring, at least well enough for me. Any labeling will be on the cables.

I also may add some cushioning between the sheet and the mounting rib on the back wall of my cab, so that may help with vibration related damage to the sheet and mounted components.

Poor savings.....better off using PVC, HDPE or ABS board. Be disappointing going to all the work and have it crack.

I've seen allot of cast/injected molded poly in electrical enclosures but in the 1-2 weeks I've been around electricity have never seen sheet used as a backing board.

 

[shade]

Poor savings.....better off using PVC, HDPE or ABS board. Be disappointing going to all the work and have it crack.

I've seen allot of cast/injected molded poly in electrical enclosures but in the 1-2 weeks I've been around electricity have never seen sheet used as a backing board.

I haven't priced options, but I doubt polycarbonate is cheaper than PVC, HDPE, or ABS. UV degradation is what I've seen damage polycarbonate more than anything else.

Like I said, I'll look into expansion issues. I recall someone skinning their flatbed with plastic and regretting their material choice as soon as it got hot. Seems like it was HDPE, but I can't recall.

What material would you recommend for a non-conductive backing board?

 

[shade]

Polycarbonate may crack around the holes while drilling and around the mounting holes if there isn't room for thermal expansion.

Cracks may form around threaded fasteners

I was also thinking more about this. Seems like oversizing the holes would allow for expansion/contraction, and could aid in reducing vibrations to the electrics.

I don't plan to thread screws directly into the material; I prefer bolts or machine screws.