Step 1: Making the Basic Shape
A) Create a sketch that is 25.4mm X 20.3mm
B) Use the "Extrude" tool under "Construct" as indicated by the arrow
To make the demesion directions more clear, they will be listed in the format: Hight X Width
Step 2: Creating Sketches for Holes
A) Create a rectangular sketch using the sketch tool that is 1.18mm X 20.3mm on the very top of one of the sides that is 20.3mm X 20.3mm, disregard the sketch of the same size on the bottom.
B) From the same view, create a sketch on the right and left side of the face that is 17.5mm X 3.7mm.
C) On the top right and left corners of the first two sketches, draw a sketch that's 6.61mm X 1.65mm (these will be used for the top prongs).
D) Using the bottom inside corners of the previously sketches, draw a new sketch that it 6.5mm X 9.6mm.
E) From the inside edges of the two outside sketches and the bottom, create a sketch that is 5.62mm X 4.0mm.
These sketches will be used to either make the plug holes or to line up the holes.
Step 3: Creating Holes for Prongs
A) Place a cylinder in the same face, the only thing that needs to be changed is the radius, which will be 2.42mm
--line the cylinder up to the edges of two sketches as indicated by the black arrows in the picture.
B) Click extrude then click on the end of the cylinder, now, type -42mm in the Extrude box, but in order to cut that distance, there will be a drop down list next to the number entry and click cut, this will create a hole for the ground prong.
C) For the two prongs on the top, again, use the the extrude tool and click on the sketch of where the hole goes and tell it to cut -17mm
--Do this for the spot where each of the two prongs goes.
Step 4: Rounding Edges and Putting Slants on Holes
A) Use the modify tool and click on fillet then click on one of the outside edges of the object and set it at a radius of 4, then do that for the other 3 edges.
B) Use the modify tool again, but this time use Chamfer and click the edges shown in the picture and set it at a Distance of 1, repeat this for the other side.
C) On the face with the openings for the prongs, on the top to, use the Chamfer as shown in the picture and set a Distance of 2.
D) Use the Chamfer tool of the hole for the Ground prong and set it at a Distance of 1.
This completes the basic design of the product
Step 5: Creating Hole for Cable Holder
A) Place a cylinder in the top back corner of the object, the radius needs to be set at 2 and the length will be the same.
B) Use the extrude and cut method as before and enter -50mm, this will allow for a hole to be put all the way through the object.
C) Use Fillet to round the edge of the hole, for this model, a radius of 0.9mm was used, repeat this step for the other side of the hole.
This step Finishes the Project