We recently introduced Samsung Andriod devices in to the work place.... but it was soon clear that the "free" wall chargers were just to much temptation for "somebody" to leave in that power board .... and they kept walking off...
So my colleague devised a simple way to keep them where they should be... So simply that the Instructable is more about sharing the idea... then how to build it....
Step 1: What You Will Need;
- Some custom wood, MDF. or Plywood board ( he used 20mm custom wood)
- bit of approx 6mm plywood
- Ruler/ pen
- Wood Glue
- Wood screws
- Wood screw driver
- A couple of roofing screws ( our fav for all purpose strong screw)
- Twist drills
- Countersink bit
- Hole saw
- Sand paper or small plane
- Power board ( number of chargers...)
Step 2: Mark and Cut
- First take the power board, add the chargers required.
- Using the ruler, work out the clearance required for the power board and chargers ( Height x Width x length)
- Calculate the size of your box using this clearance(diagram 1)
- Cut out the box pieces to your dimensions.(diagram 2)
Modification: Since building and using this for a while we discovered a problem... heat build up in side...
So we modified it, by cutting some holes along the sides and covering them on the inside with mesh screwed in to place(because in our setting the purpose was to stop people walking off with the chargers...)
Step 3: Glue or Screw
- Choose now if going to construct the box to;
- Never be opened again - gluing and screwing
- Just screwed all over
- Glued and screwed except one panel.
Step 4: Cut & Fix
- Using a hole saw just big enough to allow the power box plug to be past through the resulting hole, bore a hole in one end of the box close to the base level.
- Pass the power board plug through the hole, (diagram 5)and secure the power board mounting lugs with further screws, so it wont move around inside the box.
Step 5: Retain
- Clamp the thin piece of wood cut out, for the "plug retainer" to the centered on the underside of the lid
- Measure the diameter of the charger cables and choose a twist drill bit approx 2 mm bigger than the cable. Drill enough holes in the top of the lid to accommodate your number of charger leads ( through both bits of wood)(diagram 6)
- Un clamp the thinner "plug retainer" and set it aside.Select a twist drill size just big enough to easily pass the device end plug through, and then re drill the same holes in the top to this size(diagram 7)
- Take the "plug retainer" and cut alternate slots the same width as the diameter of the holes you drilled first - Then slip the cable down the grove and in to the hole. Push the device end plugs out through the hole in the lid.
- Just wipe enough glue on the face of the "plug retainer" to stick it to the under side of the lid, with out spreading out and filling the holes. Now position the "plug retainer so holes are centered under the larger plug holes in the lid and the cable pulls freely.. (diagram 8)Clamp. and allow glue to dry ensuring any overflow in the holes is wiped away before dry.
Step 6: Secure
- Find a good spot close to a power socket, and drill a couple of holes through the base and in to a good a bench or wall ( with out hitting the power main!) and screw that box to this surface ( now it can't walk off either)
- Now with power board secured in place, plug pushed out, chargers in slots, cables pulled through the lid... place and attach the lid.. using the method you to decided on earlier....
- Fitting the "cable retainer" was a pain.. .., but it did stop those people who now "cheated of a free charger" found great satisfaction in poking the charging cables back down the holes... amazing how people operate isn't it?