Introduction: Removable Outlet Extension
We designed this product for our co-designer with dwarfism, who has trouble reaching the outlets across her counter.
2 ft * ¾” PVC pipe
1 ¾” PVC tee joint
1 ¾” PVC elbow joint
¾” PVC cap
2 ft extension cord with 3 outlets
2 ft * 1.5 inch heat shrink wrap
Step 1: Take Measurements
First, measure the depth of the countertop that you will be using. Then, measure how far you can reach from the edge of the counter towards the outlet. Subtract the second measurement from the first measurement. In the diagram provided, this measurement is referred to as the counter-reach. Next, measure the height of the outlet that you will be using. Take this measurement from the top of the plug to the countertop, as demonstrated in the image. This measurement is referred to as the plug height in the diagram. Finally, measure the length of the plug cover on the extension cord, as shown in the image.
Step 2: Measure and Cut PVC
First, collect the 3/4 inch PVC pipe, the 3/4 inch PVC elbow joint, and the 3/4 inch PVC tee joint. For the first measurement, subtract the length of the plug covering from your counter-reach measurement, and then add .05 inches (to accommodate inserting the pipe into the elbow joint). Mark this measurement on the 3/4 inch PVC pipe. For the second measurement, subtract 4.3 inches from your plug height measurement, and mark it on the 3/4 inch PVC pipe. Then, mark a measurement of 1.75 inches on the 3/4 inch PVC pipe.
Next, using the bandsaw, cut the PVC pipe into 3 pieces of the lengths described above. Finally, cut each PVC piece, including the joints, EXCEPT for the 1.75-inch piece and the cap, horizontally so that they separate into two symmetrical pieces as shown by the image of the cut tee joint.
Step 3: Construct Device
First, using the 2 pieces of the counter-reach measurement section of PVC pipe, place one end under the cord and one end over, with one end of the pipe placed over part of the plug, as shown in the diagram. Around the plug, there will be a gap between the 2 pieces of PVC. Put a layer of superglue on the seam between the 2 pieces, and use a clamp to secure the two pieces together, as shown in the second picture, and allow to dry.
Next, complete the same process with the 2 pieces of the plug-height measurement section of PVC pipe, leaving 2 inches of exposed extension cord between the counter-reach and plug-height sections. There will not be a gap between the two pieces, because the pipe is around only extension cord. When applying glue, make sure to not get any on the cord, as this section needs to be movable.
After allowing to dry, place the elbow joint underneath the counter-reach measurement section, and move the plug-height section so that it fits within the elbow joint, as shown in the third image. Apply superglue to seal the pipes into the joint, and then place the top half of the elbow joint over the bottom half, and apply superglue to seal the two pieces together. When the superglue is dry, use SuGru to seal the space between the pipes and the joint, as shown in the fourth image.
Next, place the bottom half of the tee joint under the bottom section of the plug-height section, and bend the extension cord at a 90-degree angle so that it comes out of the tee, as shown in the fourth image. Place a layer of superglue on the seam, and place the second half of the tee joint on top, and apply pressure a clamp and allow to dry.
When dry, add a coating of superglue onto the outside of the 1.75-inch section of PVC and slide it into the bottom outlet of the tee joint, and then cap it with the 3/4-inch PVC cap.
Allow the entire project to dry completely. If any joints or connections seem weak, add a layer of epoxy and let dry.
Step 4: Finalize Product
Slide the 1.5-inch shrink wrap over the plug, and pull it over the device until it reaches the tee joint. Cut a second section of shrink wrap, with a slit on one side of the cylinder. Slide it up over the cap and the tee joint, and place the flaps under the first piece of shrink wrap. Using a heat gun, shrink the shrink wrap around the PVC.